Case CX225SR Excavator Operator’s Manual - PDF DOWNLOAD

CX225SR Excavator

Operator’s Manual Bur 6-34630na

CX225SR EXCAVATOR OPERATOR’S MANUAL

Part Number: 6-34630na

CASE TECHNICAL MANUALS Manuals are available from your Dealer for the operation, service, and repair of your machine. For prompt convenient service, contact your Dealer for assistance in obtaining the manuals for your machine.

Your Dealer can expedite your order for Operator’s Manuals, Parts Catalogs, Service Manuals, and Maintenance records.

Always give the Machine Name, Model, and P.I.N. (Product Identification Number) or S.N. (Serial Number) of your machine so your Dealer can provide the correct manuals for your machine.

NOTE: Case Corporation reserves the right to make improvements in design or changes in specifications at any time without incurring any obligation to install them on units previously sold.

THIS SAFETY ALERT SYMBOL INDICATES IMPORTANT SAFETY MESSAGES IN THIS MANUAL. WHEN YOU SEE THIS SYMBOL, CAREFULLY READ THE MESSAGE THAT FOLLOWS AND BE ALERT TO THE POSSIBILITY OF DEATH OR SERIOUS INJURY M171D

Safety Decals on this machine use the words Danger, Warning, or Caution, which are defined as follows: DANGER: Indicates an immediate hazardous situation that, if not avoided, will result in death or serious injury. The color associated with Danger is RED. WARNING: Indicates a potentially hazardous situation that, if not avoided, could result in death or serious injury. The color associated with Warning is ORANGE. CAUTION: Indicates a potentially hazardous situation which, if not avoided, may result in minor or moderate injury. It may also be used to alert against unsafe practices. The color associated with Caution is YELLOW. If Safety Decals on this machine are ISO two panel Pictorial, decals are defined as follows: The first panel indicates the nature of the hazard.

The second panel indicates the appropriate avoidance of the hazard.

Background color is YELLOW Prohibition symbols such as

and

STOP

if used, are RED.

IMPROPER OPERATION OF THIS MACHINE CAN CAUSE DEATH OR SERIOUS INJURY. BEFORE USING THIS MACHINE, MAKE CERTAIN THAT EVERY OPERATOR: Is instructed in safe and proper use of the machine.

Reads and understands the Manual(s) pertaining to the machine.

Reads and understands ALL Safety Decals on the machine.

Clears the area of other persons.

Learns and practices safe use of machine controls in a safe, clear area before operating this machine on a job site.

It is your responsibility to observe pertinent laws and regulations and follow Case Corporation instructions on machine operation and maintenance.

WARNING_01_NA

CALIFORNIA PROPOSITION 65 WARNING Diesel engine exhaust and some of its constituents are known to the State of California to cause cancer, birth defects, and other reproductive harm.

Battery post, terminals and related accessories contain lead and lead compounds.

Wash hands after handling.

Copyright © 2002 Case Corporation All Rights Reserved CASE and IH are registered trademarks of Case Corporation

Bur 6-34630naNA Issued October, 2002

TABLE OF CONTENTS CHAPTER 1 GENERAL INFORMATION To The Owner . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-1 Machine Components . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-3 Identification Numbers . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-5 CHAPTER 2 SAFETY, DECALS, AND HAND SIGNALS Table of Contents . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-1 Safety Rules . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-3 Personal Safety . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-4 Safety Area . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-4 Utility Safety . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-4 Operator Precautions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-5 Decals . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-10 Hand Signals . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-15 CHAPTER 3 INSTRUMENTS AND CONTROLS Table of Contents . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-1 Cab Door . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-3 Steps and Access Handles . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-4 Position of the Operator’s Compartment Controls and Accessories . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-5 Right-hand Control Arm . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-6 Instrument Panel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-7 Left-hand Control Arm . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-9 Working Light Switch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-10 Windshield Washer Switch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-10 Windshield Wiper Switch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-10 High Speed Travel Switch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-10 Heating, ventilation and air-conditioning control . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-11 Function cancellation Lever . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-12 Arm and Upperstructure Swing Left-hand Control Lever . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-12 Boom and Bucket Right-hand Control Lever . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-13 Travel Control . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-14 Option Pedal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-15 Unlocking and Locking of Pedals . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-15 Cab Light . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-15 Coat Hanger Hook . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-16 Rear Right-hand Side Window . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-16 storage Compartment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-17 Storage Tray . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-17 Ashtray . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-17 Cab Radio Compartment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-17 Speaker Compartments . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-17 Fuse Box . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-17 Operator's Seat . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-18 Windshield . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-21 Lower Front Window . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-22 Window-Breaker Hammer . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-22 Air Vents . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-22

6-34630naNA

Issued 10-02 Bur

I

Rear View Mirrors . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Fuel Tank . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Upper Hood . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Engine Hood . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Windshield Washer Reservoir . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Side Doors . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Lower panels . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Towing Point . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Load Handling Eyes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Tool Supply Valves (Optional) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Optional tool flow selector valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

3-23 3-24 3-24 3-25 3-25 3-26 3-26 3-26 3-27 3-28 3-28

CHAPTER 4 OPERATING INSTRUCTIONS Table of Contents . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-1 Before Operating the Machine . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-3 Operating the Machine . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-3 Run-in Period . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-4 Hydraulic Fluid Warm-up . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-4 Starting the engine . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-5 Bringing the Machine up to Operating Temperature . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-6 Engine Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-7 Stopping the Engine . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-7 Operating the Machine in Cold Weather . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-8 Operating the Machine in Hot Weather . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-9 Basic operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-9 Machine Travel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-10 Transporting the Machine . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-12 Handling the Machine . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-15 Operating the Machine In Water . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-15 Parking the Machine . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-15 Operating the Machine on Sloping Ground . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-16 Towing the Machine . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-16 Operating the Bucket . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-17 Lowering the attachment in the event of a machine failure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-18 Auxiliary hydraulic circuits . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-19 Machine storage . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-21 CHAPTER 5 LUBRICATION, FILTERS, AND FLUIDS Table of Contents . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-1 Servicing Instructions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-3 Daily Inspections . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-3 Hourmeter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-4 Lubrication chart . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-5 Fluids and Lubricants . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-6 Fluid and Lubricant Capacities and Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-8 Lubrication Points . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-9 Fluid Levels . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-13 Engine . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-14 Cooling System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-16 Fuel System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-18 Releasing Pressure in the Hydraulic System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-21 Hydraulic System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-22 Air Filter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-30 Swing Reduction Gear . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-33 Travel Reduction Gears . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-34 II

Issued 10-02

Bur

6-34630naNA

CHAPTER 6 MAINTENANCE AND ADJUSTMENTS Table of Contents . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-1 Tracks . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-3 Track Rollers and Idler Wheels . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-6 Radiator and Oil Cooler . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-7 Fan and Alternator Drive Belt . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-8 Fuel Tank Filter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-9 Inspecting and Cleaning the Machine . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-9 adjusting rocker arm clearance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-9 Checking for Cylinder Leakage . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-9 Replacing a Bucket . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-10 Fire Extinguisher (Not Supplied) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-11 Welding on the Machine . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-11 Plastic and Resin Parts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-11 Air conditioning . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-12 Hardware torque inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-14 CHAPTER 7 ELECTRICAL Table of Contents . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Fuses . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Battery . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Connecting One Or Two Booster Batteries . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Alternator . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Starter Motor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Replacing a Bulb . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Adjusting The Working Lights . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

7-1 7-3 7-5 7-7 7-7 7-7 7-8 7-9

CHAPTER 8 SPECIFICATIONS Table of Contents . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Engine . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Electrical Systems . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Hydraulic System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Capacity of Systems and Components . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Weights . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Ground Pressure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Attachment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Arms . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Esco Buckets . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Machine Overall Dimensions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Working Range . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

8-1 8-3 8-3 8-3 8-4 8-4 8-4 8-4 8-4 8-5 8-6 8-8

CHAPTER 9 INDEX

6-34630naNA

Issued 10-02 Bur

III

IV

Issued 10-02

Bur

6-34630naNA

CHAPTER 1 - GENERAL INFORMATION

Chapter 1 GENERAL INFORMATION TO THE OWNER

Figure 1

CT02E021

HYDRAULIC CRAWLER EXCAVATORS SERIES CX225SR

Your machine has been designed and built to the highest standards of quality. It conforms to all current safety regulations. See Official documents. However, the risk of accidents can never be completely excluded. That is why it is essential to observe elementary safety rules and precautions.

Read this manual carefully, paying particular attention to the instructions concerning safety, operation and maintenance so as to avoid the risk of injury while operating or servicing the machine.

The standard attachments and tools of this machine are designed to carry out all kinds of earthmoving and rehandling operations. If you want to use this machine to handle a load (pipes, culverts, formwork, etc.), make sure that it is designed to carry out this kind of work. For this type of application, the machine must be equipped with safety valves, an overload indicator, a load handling chart corresponding to the type of machine and its attachment and a load fixing point. All legal requirements must also be strictly observed.

Do not use this machine for any application or purpose other than those described in this manual. If the machine is to be used for work involving the use of special attachments, accessories or equipment, consult your CASE Dealer in order to make sure that any adaptations or modifications made are in keeping with the machine's technical specifications and with prevailing safety requirements.

Any modification or adaptation which is not approved by the manufacturer may invalidate the machine's initial conformity with safety requirements.

6-34630naNA

Issued 10-02 Bur

1-1

CHAPTER 1 - GENERAL INFORMATION The machine must undergo regular inspections, the frequency of which varies according to the type of use. Consult your CASE Dealer.

Before permitting a new operator on this machine, make sure: 1. That the operator has received the necessary training on how to operate the machine correctly and safely.

2. That the operator has read and understood the instructions given in this manual.

Always keep this manual in the operator's compartment (in the seat back, behind the operator's seat). Make sure it is always complete and in good condition. If you wish to obtain extra copies, or copies in languages other than that of the country of use, consult your CASE Dealer.

Your CASE Dealer is at your disposal for any further information. He will also provide any after-sales service you may require, and genuine CASE spare parts, your guarantee of quality and match.

1-2

Issued 10-02

Bur

6-34630naNA

CHAPTER 1 - GENERAL INFORMATION

MACHINE COMPONENTS 9 6

11 5

7

12

20 19 8

1

5 2

13 14

10 3 18

17 4

16

15 Figure 2

CT02E021

1.

2.

3.

4.

5.

6.

7.

8.

CAB/OPERATOR'S COMPARTMENT UPPERSTRUCTURE UNDERCARRIAGE STEPS ACCESS HANDLES BOOM BOOM CYLINDERS ARM

9.

10.

11.

12.

13.

14.

15.

16.

ARM CYLINDER BACKHOE BUCKET BACKHOE BUCKET CYLINDER ENGINE COMPARTMENT COUNTERWEIGHT UPPER ROLLERS LOWER ROLLERS TRAVEL REDUCTION GEARS

17.

18.

19.

20.

IDLER WHEELS TRACKS HYDRAULIC RESERVOIR FUEL TANK

MAIN COMPONENTS

The CX225SR is a fully hydraulic machine. It consists of an undercarriage fitted with tracks and a turntable bearing which supports the upperstructure frame. The upperstructure frame supports the attachment, at the front end of the machine, plus the engine, hydraulics and cab. When the operator works the controls, the engine-driven pump delivers hydraulic fluid to the control valves. The control valves distribute the hydraulic fluid to the various cylinders and motors concerned. A cooling system maintains the hydraulic fluid at normal operating temperature.

6-34630naNA

Issued 10-02 Bur

1-3

CHAPTER 1 - GENERAL INFORMATION RIGHT, LEFT, FRONT AND REAR OF THE MACHINE The terms Right-hand, Left-left, Front, and Rear are used in this manual to indicate the sides as they are seen from the operator's seat when the cab is over the idler wheels.

1

The illustration below shows the machine in normal TRAVEL position. In normal TRAVEL position, the cab is over the idler wheels. The travel reduction gears are at the rear of the upperstructure.

6

6

4

3

5

5 2

CT02D269

1.

2.

3.

4.

5.

6.

1-4

Figure 3

FRONT REAR RIGHT-HAND SIDE LEFT-HAND SIDE TRAVEL REDUCTION GEARS IDLER WHEELS

Issued 10-02

Bur

6-34630naNA

CHAPTER 1 - GENERAL INFORMATION

IDENTIFICATION NUMBERS TYPE, SERIAL NUMBER AND YEAR OF MANUFACTURE When ordering parts, obtaining information or assistance, always supply your CASE Dealer with the type and serial number of your machine or accessories.

Write the following in the spaces below: The type, serial number and year of manufacture of your machine, accessories and the serial numbers of the various hydraulic and mechanical components.

Machine

Figure 4

Engine

Engine

Make and Model

Serial Number

Figure 5

CT02E023

COMPONENT SERIAL NUMBERS Hydraulic pump............................................................................................................................................................

Swing reduction gear...................................................................................................................................................

Travel reduction gears .................................................................................................................................................

Travel control valve ......................................................................................................................................................

Attachment control valve .............................................................................................................................................

Swing control valve......................................................................................................................................................

6-34630naNA

Issued 10-02 Bur

1-5

CHAPTER 1 - GENERAL INFORMATION

NOTES

1-6

Issued 10-02

Bur

6-34630naNA

CHAPTER 2 - SAFETY, DECALS, AND HAND SIGNALS

Chapter 2 SAFETY, DECALS, AND HAND SIGNALS TABLE OF CONTENTS SAFETY RULES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-3 PERSONAL SAFETY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-4 SAFETY AREA . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-4 UTILITY SAFETY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-4 OPERATOR PRECAUTIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-5 Personnel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-5 General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-5 Mounting and Dismounting Precautions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-5 Starting and Stopping Precautions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-5 Operating Precautions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-6 Maintenance Precautions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-7 Fuel Handling Precautions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-7 Burn Prevention . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-8 Hazardous Chemical Precautions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-8 Transporting Precautions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-8 Wheel, Tire, and Track Safety . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-8 Roll-Over Protective Structure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-8 Fire Extinguisher . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-8 Seat Belt Precautions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-9 Specific Precautions to this Machine . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-9 DECALS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-10 HAND SIGNALS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-15

Issued 10-02

Bur

6-34630NA

2-1

CHAPTER 2 - SAFETY, DECALS, AND HAND SIGNALS

NOTES

2-2

Issued 10-02

Bur

6-34630NA

CHAPTER 2 - SAFETY, DECALS, AND HAND SIGNALS

SAFETY RULES WARNING: This safety alert symbol indicates important safety messages in this manual. When you see this symbol, carefully read the message that follows and be alert to the possibility of death or serious injury.

M171C

Most accidents involving machine operating and maintenance can be avoided by following basic safety rules and precautions. Read and understand all the safety messages in this manual, the safety manual and the safety signs on the machine before you operate or service the machine. See your dealer if you have any questions.

1

Figure 1

RD98K305

1. OPERATOR’S MANUAL STORAGE BOX

READ THIS MANUAL COMPLETELY and make sure you understand the controls. All equipment has a limit. Make sure you understand the speed, brakes, steering, stability and load characteristics of this machine before you start to operate.

DO NOT remove this manual or the safety manual from the machine. See your dealer for additional manuals. Also see the manual information on the inside of the rear cover of this manual.

The safety information given in this manual does not replace safety codes, insurance needs, federal, state or local laws. Make sure that your machine has the correct equipment according to these rules or laws.

Additional safety messages are used in the text of the manual to show specific safety hazards.

IMPORTANT: The safety messages in this chapter point out situations which can happen during the normal operation and maintenance of your machine.

These safety messages also give possible ways of dealing with these conditions.

6-34630NA

Issued 10-02 Bur

2-3

CHAPTER 2 - SAFETY, DECALS, AND HAND SIGNALS

PERSONAL SAFETY If Safety Decals on this machine are ISO two panel Pictorial, decals are defined as follows:

· The first panel indicates the nature of the hazard. · The second panel indicates the appropriate avoidance of the hazard.

· Background color is YELLOW Prohibition symbols such as used, are RED.

and

STOP

if

ALWAYS have all local utility companies mark the location of their lines.

In U.S.A. and Canada call one of many “One Call System Director” services. If you do not know the local number, call the national number (U.S.A. and Canada only): 1-888-258-0808.

Check with local authorities for laws, regulations and/or strict penalties requiring you to locate and avoid existing utilities.

SAFETY AREA

1

Figure 2

CS97M019

1. WORKING AREA 2. SAFETY AREA

The safety area is the space necessar y for the machine to operate at the maximum range of the tool and a full 360 ° swing plus 6 feet (2 metres).

UTILITY SAFETY Safety precaution MUST be followed when working near buried and over head Utility Lines.

During operation it is likely that you will be working around or near buried or over head utility lines which may include, but are not limited to:

· · · ·

Figure 3

RH99G001

2

Electrical Power Line

CALL ALL LOCAL UTILITY COMPANIES BEFORE YOU PERFORM ANY MACHINE OPERATION

Know the utility color code (U.S.A. and Canada): Electric. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Red Gas, Oil, or Petroleum . . . . . . . . . . . . . . . . . . . Yellow Communication, Telephone, Television . . . . . Orange Water . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Blue Sewer . . . . . . . . . . . . . . . . . . . . . . . . . .Green/Brown Proposed Excavation. . . . . . . . . . . . . . . . . . . . .White Surveying . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Pink Reclaimed Water and Slurry . . . . . . . . . . . . . . Purple After locating any buried utility lines, carefully dig a hole by hand and/or automatic vacuum equipment to the utility line to verify the location and depth of the line.

Gas Line Water Line Communication Television

Line

-

Telephone

or

Cable

Before beginning any machine operation, it is your responsibility to be aware of all such utility lines buried and over head in the area of your project and to avoid them.

2-4

Issued 10-02

Bur

6-34630NA

CHAPTER 2 - SAFETY, DECALS, AND HAND SIGNALS

OPERATOR PRECAUTIONS

MOUNTING AND DISMOUNTING PRECAUTIONS

· Use the recommended hand holds and steps with

PERSONNEL

· Be prepared for emergencies. Always have a first aid kit and a working fire extinguisher with you and know how to use each.

· Avoid loose fitting clothing, loose or uncovered long hair, jewelry and loose personal articles.

· Know and use the protective equipment that is to be worn when operating this machine. Hard hats, protective glasses, protective shoes, gloves, reflector type vests, respirators and ear protection are examples of typed of equipment that may be required.

· Certain protective equipment should be replaced

at leas three points of support when getting on and off the machine. Keep steps and platform clean.

Face the access system when climbing up and down

· Do not jump off the machine. · Do not dismount while the machine is in motion. · Foreign material or grease on the steps and hand rails can cause an accident. Keep the steps and hand rails clean.

STARTING AND STOPPING PRECAUTIONS

· Walk around the machine and warn all personnel who may be servicing the machine or are in the machine path prior to starting. Do not start until all personnel are clearly away from the machine.

Sound the horn, if equipped, before starting.

and renewed upon age and wear. Old hard hats may not afford the original users intention. Faded and soiled vest are no longer as highly visible as original intent.

See the manufacture’s recommendation.

· Walk around the machines tool, attachment, or

· Do not rush. Walk, do not run. · Know and use the hand signals required for

· Check that the parking device is applied, place the

particular jobs and know responsibility for signaling.

who

has

the

GENERAL

· It is the responsibility of the operator to read and

furthermost contact point to view operation danger area from the worksite personnel view and angle. transmission in neutral or park as specified by the manufacturer, and disengage the PTO, if so equipped, before starting the machine.

· Adjust, secure and latch the seat and fasten the seat belt before starting the machine.

understand the Operator’s Manual and other information provided and use the correct operating procedure. Machines should be operated only by qualified operators.

· Start and operate the machine only from the

· Do not operate this machine or perform

The neutral-start system must be repaired if it malfunctions.

maintenance work if you have not had appropriate training and read and fully understand the instructions and warnings in this manual.

· Wear the seat belt to maximize the protection capability of a ROPS (Roll Over Protective Structure) when the machine is so equipped.

· Inspect the ROPS and seat belt mounting bolts on a daily basis to ensure their integrity.

· Do not permit riders on the machine if there is no manufacturer’s designated place for a rider.

· Make sure that all protective guards, canopies, doors, etc. are in place and secure.

· Remove all loose object stored in the machine.

Remove all objects which do not belong in or on the machine and its equipment.

operator’s station.

· Do not bypass the machine’s neutral-start system. · Use jumper cables only in the recommended manner. Improper use can result in battery explosion or unexpected machine motion.

Ventilate the battery area before using jumper cables. Make sure that using jumper cables will not interfere or harm electronic processing or computer devices.

· Do not operate the engine in an enclosed area without adequate ventilation.

· Park the machine on level ground whenever possible and apply the parking brake. On grades, park the machine with the wheels or track securely blocked.

· Before leaving the operator’s station, place the transmission in the park position as specified by the manufacturer, lower the equipment to the ground or put in the locked position, disengage the PTO, if so equipped, set the parking device and shut off the engine.

· Remove the starter key or disconnect switch when leaving the machine parked or unattended.

6-34630NA

Issued 10-02 Bur

2-5

CHAPTER 2 - SAFETY, DECALS, AND HAND SIGNALS OPERATING PRECAUTIONS

· Check brakes, steering and other machine control devices in accordance with the manufacturers instructions prior to starting operation. Observe all gauges or warning instruments for proper operation. Operate all controls to insure proper operation. If any malfunctions are found, remove the starter key or disconnect switch key. Place a do not operate tag on the machine until the malfunction is corrected.

· If a failure that causes loss of control such as steering, service brakes or engine occurs, stop the machine motion as quickly as possible, remove the starter key or disconnect switch key. Place a do not operate tag on the machine and keep it securely parked until the malfunction is corrected or the machine can be safely towed.

· Understand the machine limitations and keep the machine under control.

· Operate and drive the machine with care and at speed compatible with conditions. Use extra caution when operating over rough ground, on slopes, and when turning.

· Note and avoid all hazards and obstructions such as ditches, underground lines, trees, cliffs, overhead electrical wires or areas where there is danger of a slide.

· Carry loads in recommended positions for maximum stability.

· Never lift loads in excess of capacity. · Use the recommended machine ballast and counterweighting.

· Know and understand the job site traffic flow

· Use the recommended transport devices when roading the machine.

· Use the approved drawbar and / or attachment point when using the machine for towing. If a cable or chain is used, keep people away from the tow line.

· Before you operate at night, check that all lamps illuminate.

· Engine exhaust fumes can cause death. If you operate this machine in an enclosed area, make sure there is ventilation to replace the exhaust fumes with fresh air.

· If your machine has a cab make sure that all windows are clean and that the windshield wipers work correctly.

· Check all controls in a clear area and make sure the machine is operating correctly.

· Dust, fog, smoke, etc., can decrease your vision and cause an accident. Stop the machine or decrease the speed until you can see.

· Contact

with high voltage power lines, underground cables, etc., can cause serious injury or death from electrocution.

· Before you drive or operate in an area with high voltage lines, cables, or a power station, tell the power or utility company what you are going to do.

You MUST HAVE THE POWER DISCONNECTED OR KEEP A SAFE WORKING DISTANCE from the lines, cables, or power station. Keep all parts of the machine at least 4.6 m (15 feet) away from the power source. You must also know any federal, state/provincial, or local safety codes or regulations that apply to the job site.

patterns and obey signalmen, road signs and flagmen.

· If a part of the machine touches high voltage

· Know and understand that job site conditions may

1. Warn other workers NOT TO TOUCH THE MACHINE and to stay away from the machine.

change on an hourly basis. Hills of dirt, debris or obstructions may grow and change from the time you began the day. It is your responsibility to monitor the changes and keep the machine, tools and attachments, etc. a safe distance.

· Watch for bystanders and never allow anyone to be under or to reach through the machine and its equipment while operating.

· Select a gear that will prevent excessive speed when going downhill. Do not coast downhill.

· When roading a machine, know and use the

power:

2. If you can break contact, reverse the operation that caused contact with the high voltage power, and move the machine away from the danger area. If you cannot break contact stay in the machine until the utility company de-energizes the line and tells you that the power is off.

· If you have extreme conditions, such as a fire, etc., and you are forced to leave the machine, do not step off the machine. Jump as far from the machine as possible with your feet together and do not touch the ground with your hands.

signaling devices required on the machine.

Provide and escort for roading where required.

· Do not operate the machine if you do not feel well.

· On machines with independently operated wheel

This can be dangerous for you and for the people around you.

brakes, lock the brake pedals together when roading to provide equalized brake application.

· You must make a judgment if weather, road, or earth conditions will permit safe operation on a hill, ramp, or rough ground.

2-6

Issued 10-02

Bur

6-34630NA

CHAPTER 2 - SAFETY, DECALS, AND HAND SIGNALS

· Stay away from hazardous areas such as ditches,

· Never make repairs on pressurized components,

overhangs, etc. Walk around the work area before you start and look for hazards.

fluid, gas or mechanical until the pressure has been relieved according to the manufacturer’s instructions.

· Be alert and always know the location of all workers in your area. Keep all other persons completely away from your machine. Injury or death can result if you do not follow these instructions.

· Use extreme caution when removing radiator caps, drain plugs, grease fittings or pressure taps.

Park the machine and let it cool down before opening a pressurized tank.

· Release all pressure before working on systems

MAINTENANCE PRECAUTIONS

· Do not attempt repairs unless trained. Refer to manuals and experienced repair personnel for help.

· Before you service the machine, put a Do Not Operate tag on the key switch. The Do Not Operate tag is included with your new machine.

Addition tags, part number 321-4614 are available from your Case dealer.

which have an accumulator. Use a piece of cardboard, newspaper, or wood to check for pressurized leaks to prevent fluid penetrating the skin. Pressurize accumulators with the proper gas according to manufacturers. recommendations.

· When inflating tires, use a self-attaching inflation chuck with remote shutoff and stand clear of the tire. Position yourself beside the tire and not beside the rim.

· When absolutely necessary to tow the machine, do not exceed the recommended towing speed. Be sure the towing machine has sufficient braking capacity to stop the towed load. If the towed machine cannot be braked, a towbar must be used or two towing machines must be used. - one in front pulling and one in the rear to act as a brake.

Avoid towing over long distances.

· Observe proper maintenance procedures. · Whenever servicing or replacing hardened pins, etc, use a brass drift or other suitable material between the hammer and pin. Alt: Use a brass hammer, drift or suitable material on the pin, etc.

321-4614

Figure 4

· Wear protective glasses and other required safety equipment machine.

when

servicing

or

repairing

the

· Wear gloves to protect hands when handling cable.

· Disconnect the battery before working on the electrical system. Know the consequences of disconnecting any electronic or computer devices.

· Avoid lubrication or mechanical adjustments with the machine in motion or the engine operating. If the engine must be in operation to make certain adjustments, place the transmission in neutral, apply the parking device, place the equipment in a safe position, securely block the wheels and use extreme caution.

· Securely block the machine or any component that may fall before working on the machine or component. If possible, use a back up or secondary blocking device, also.

· To prevent unexpected movement, securely block

· Keep the brakes and steering systems in good operating condition.

· Replace all missing, illegible or damaged safety signs. Keep all safety signs clean.

FUEL HANDLING PRECAUTIONS

· Do not smoke or permit open flames while fueling or near fueling operations.

· Never remove the fuel cap or refuel gasoline engine powered machines with the engine running or hot. Never allow fuel to spill on hot machine components. Never allow fuel to spill on the environment.

· To avoid spilling fuel maintain control of the fuel filler nozzle when filling the tank.

· Do not fill the fuel tank completely to the top. Allow room for expansion.

· Clean up spilled fuel immediately and dispose of contaminated material in an environmentally correct manner.

working elements when repairing or changing working tool parts such as cutting edges.

6-34630NA

Issued 10-02 Bur

2-7

CHAPTER 2 - SAFETY, DECALS, AND HAND SIGNALS

· Tighten the fuel tank cap securely. Should the fuel

· Before you service your machine, check the

cap be lost, replace it only with the original manufacturers approved cap. Use of a non-approved cap without proper venting may result in pressurization of the tank.

MSDS for each fluid, lubricant, etc., used in this machine. This information indicates what the risks are and how to service the machine safely. Follow this information when servicing the machine.

· Never use fuel for cleaning purposes. · Use the correct fuel grade for the operating

· Before you service this machine and before you

season.

BURN PREVENTION

dispose of the old fluids and lubricants, always remember the environment. DO NOT put oil or fluids into the ground or into containers that can leak.

· Check with your local environmental or recycling

WARNING: BATTERY ACID CAUSES SEVERE BURNS. Batteries contain sulfuric acid. Avoid contact with skin, eyes or clothing.

Antidote: EXTERNAL - Flush with water.

Antidote: INTERNAL - Drink large quantities of water or milk.

DO NOT induce vomiting. Seek medical attention immediately.

EYES - Flush with water for 15 minutes and seek medical attention immediately.

WARNING: BATTERIES PRODUCE EXPLOSIVE GASES. Keep sparks, flame, cigars and cigarettes away. Ventilate when charging or using in enclosed area. Always wear eye protection when working near batteries. Wash hands after handling. KEEP OUT OF REACH OF CHILDREN. M144B

· When the battery electrolyte is frozen, the battery can explode if, you try to charge the battery, or you try to jump start and run the engine. To prevent the battery electrolyte from freezing, try to keep the battery at full charge. If you do not follow these instructions, you or others in the area can be injured

· Hot coolant can spray out if the radiator cap is

center or your information.

dealer

for

correct

disposal

TRANSPORTING PRECAUTIONS

· Know the rules, laws, and safety equipment necessary for transporting this machine on a road or highway.

WHEEL, TIRE, AND TRACK SAFETY

· Explosive separation of the tire and/or rim parts can cause injury or death. When tire service is necessary, have a qualified tire mechanic service the tire.

ROLL-OVER PROTECTIVE STRUCTURE

· Do NOT modify the ROPS in any manner.

Unauthorized modifications such as welding, drilling, cutting, or adding attachments can weaken the structure and reduce your protection. Replace ROPS if it is subjected to roll-over or damage. Do not attempt to repair.

FIRE EXTINGUISHER It is recommended that you have a fire extinguisher on your machine. The fire extinguisher shown is available from your dealer and can be installed on the machine.

removed. To remove the radiator cap, let the cooling system cool, turn to the first notch, wait until the pressure is released, then remove the radiator cap.

HAZARDOUS CHEMICAL PRECAUTIONS

· If you are exposed to or come in contact with hazardous chemicals you can be seriously injured.

The fluids, lubricants, paints, adhesives, coolants, etc., used with your machine can be hazardous.

· Material Safety Data Sheets (MSDS) provide information about the chemical substances within a product, safe handling procedures, first aid measures and procedures to be taken when the product is accidentally spilled or released. MSDS are available from your dealer.

2-8

Issued 10-02

Bur

6-34630NA

CHAPTER 2 - SAFETY, DECALS, AND HAND SIGNALS SEAT BELT PRECAUTIONS

2

1

3 Figure 5

CD00E032

1. RIGHT BELT STRAP 2. LATCH MECHANISM 3. RELEASE BUTTON

1. To latch the seat belt, pull the right belt strap from the retractor.

2. Insert the metal end into the latch mechanism on the left side of the seat.

3. To unlatch the seat belt, press the red button on the left side latch mechanism.

4. The seat belt will automatically retract.

WARNING: Before starting the engine ensure seat belts are securely fastened. The seat belt can help insure your safety if it is used and properly maintained. Never wear a seat belt loosely or with slack in the belt system. Never wear the belt in a twisted condition or pinched between the seat structural members.

M422A

WARNING: Securely fasten your seat belt.

Your machine is equipped with a ROPS cab, ROPS canopy or ROPS frame for your protection. The seat belt can help insure your safety if it is used and maintained. Never wear a seat belt loosely or with slack in the belt system. Never wear the belt in a twisted condition or pinched between the seat structural members.

M437

SPECIFIC PRECAUTIONS TO THIS MACHINE

· Keep the load or tool as low as possible while moving the machine around the jobsite.

· Never smoke while refuelling.

6-34630NA

Issued 10-02 Bur

2-9

CHAPTER 2 - SAFETY, DECALS, AND HAND SIGNALS

DECALS WARNING: An illegible or missing decal can have far-reaching consequences. Inspect decals daily.

WARNING: Make sure that the decals are perfectly legible, clean them regularly and replace decals that are destroyed, lost, painted over or no longer legible, with new ones. When parts bearing decals are replaced, be sure to put new decals on each new part.

NOTE: When you clean the decals, use only a cloth, water and soap. Do not use solvents, gasoline, etc.

NOTE: This chapter only covers decals relating to safety and machine operation and servicing. For information on all decals for the machine, consult your authorized dealer.

Figure 8

KHP1533-00

This decal warns of the hazard associated with rotating parts and components.

Figure 9

Figure 10

KHP1013

KHP1537-00

Figure 6

T h i s 3 p a n e l d e c a l ex p l a i n s t h e D a n g e r o f electrocution, the impor tance of reading and understanding the operator’s manual and that attachment interference may cause damage to the operator’s compartment.

This decal instructs the operator to use diesel fuel only.

Figure 11

KHP1535

BS00M141

Figure 7

This decal cautions that some surfaces may cause burns.

This decal warns of Danger and to keep clear of swinging upperstructure to prevent serious bodily injury.

2-10

Issued 10-02

Bur

6-34630NA

CHAPTER 2 - SAFETY, DECALS, AND HAND SIGNALS

Figure 12

321-6718

This decal war ns that improper jumper cable connections may cause the machine to move out of control causing serious injury or death.

Figure 13

321-7040

This decal warns that starting in gear can cause serious injury or death and the engine should be started from the operator’s seat only.

6-34630NA

Issued 10-02 Bur

167327A1

Figure 14

This decal warns the operator or technican that grease may be under heavy pressure and cause serious injury or death.

167328A1

Figure 15

This decal reminds the operator or technican of procedures for checking the Hydraulic fluid level.

2-11

CHAPTER 2 - SAFETY, DECALS, AND HAND SIGNALS

Figure 18

CS00F530 167324A1

Figure 16

This decal warns of the Danger if standing too close to a machine that becomes electrified.

This decal shows the function of the left-hand and right-hand control levers.

Figure 19

BS02G143

This decal warns the operator to change the function decal in the cab to match the control pattern setting.

KHP1536

Figure 17

This decal war ns of the hazards that may be encountered when servicing the batteries and using jumper cables.

Figure 20

KHP1498

This decal shows the function of the travel control levers and pedals.

2-12

Issued 10-02

Bur

6-34630NA

CHAPTER 2 - SAFETY, DECALS, AND HAND SIGNALS

Figure 21

KHP1542

This decal warns that hot hydraulic fluid or hydraulic fluid under pressure may cause burns or bodily injury. See Releasing Hydraulic Pressure in this manual.

CS98N560

Figure 24

This decal shows the location and way to use the emergency exit. (rear window)

Figure 22

CT02C010

This decal warns that the radiator system must be allowed to cool and pressure must be released before removing the radiator cap.

BS00M132

Figure 25

This decal cautions that contact may be made between the attachment and backfill blade during certain digging operations.

Figure 23

321-3596

This decal warns to keep clear of rotating fans and belts.

6-34630NA

Issued 10-02 Bur

2-13

CHAPTER 2 - SAFETY, DECALS, AND HAND SIGNALS

KHP-1010-00

Figure 26

This decal cautions that the hood must be locked into positon to avoid serious injury.

2-14

Figure 27

KHP1011-00

This decal cautions not to walk on engine cover.

Issued 10-02

Bur

6-34630NA

CHAPTER 2 - SAFETY, DECALS, AND HAND SIGNALS

HAND SIGNALS When operating the machine, never attempt to carry out tasks calling for fine control or to work in areas where visibility is poor or impaired without seeking the assistance of a signalman. Make perfectly sure that you and the signalman understand the signals to be used.

Figure 28

PDE0002A

GO THIS FAR

Figure 29

PDE0002

Figure 32

PDE0004A

START THE ENGINE

Figure 33

PDE0005A

SHUT DOWN THE ENGINE

RAISE LOAD OR TOOL

Wave hands back and forth.

Figure 30

PDE0003A

COME TO ME

Wave hands back and forth (palms inwards).

ALL STOP AND HOLD

Figure 31

PDE0003

MOVE AWAY FROM ME

Wave hands back and forth (palms outwards).

6-34630NA

Issued 10-02 Bur

Figure 34

PDE0004

Figure 35

PDE0005

EMERGENCY STOP

Wave hands back and forth.

2-15

CHAPTER 2 - SAFETY, DECALS, AND HAND SIGNALS

Figure 36

PDE0006A

RAISE LOAD OR TOOL

RAISE TOOL

Figure 37

PDE0006

Figure 40

PDE0009A

LOWER LOAD OR TOOL

Figure 41

PDE0008A

TURN THE MACHINE TO THE LEFT (SWING LOAD LEFT)

To stop movement, stop moving hand and clench fist.

Figure 38

PDE0007A

SLOWLY RAISE THE LOAD OR TOOL

Figure 42

PDE0008

TURN MACHINE RIGHT (SWING LOAD RIGHT)

To stop movement, stop moving hand and clench fist.

PDE0007

Figure 39 SLOWLY LOWER THE LOAD OR TOOL PDE0009

Figure 43 LOWER TOOL

2-16

Issued 10-02

Bur

6-34630NA

CHAPTER 2 - SAFETY, DECALS, AND HAND SIGNALS

Figure 44

PDE0010A

RAISE TOOL

EXTEND ARM

Figure 45

PDE0010

6-34630NA

FILL TOOL

Figure 46 RETRACT ARM

Issued 10-02 Bur

Figure 48

PDE0012A

LOWER TOOL

PDE0011A

Figure 47

PDE0011

Figure 49

PDE0012

EMPTY TOOL

2-17

CHAPTER 2 - SAFETY, DECALS, AND HAND SIGNALS

NOTES

2-18

Issued 10-02

Bur

6-34630NA

CHAPTER 3 - INSTRUMENTS AND CONTROLS

Chapter 3 INSTRUMENTS AND CONTROLS TABLE OF CONTENTS CAB DOOR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-3 STEPS AND ACCESS HANDLES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-4 POSITION OF THE OPERATOR’S COMPARTMENT CONTROLS AND ACCESSORIES . . . . . . . . . . . . . . . . 3-5 RIGHT-HAND CONTROL ARM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-6 INSTRUMENT PANEL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-7 LEFT-HAND CONTROL ARM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-9 WORKING LIGHT SWITCH . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-10 WINDSHIELD WASHER SWITCH . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-10 WINDSHIELD WIPER SWITCH . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-10 HIGH SPEED TRAVEL SWITCH . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-10 HEATING, VENTILATION AND AIR-CONDITIONING CONTROL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-11 FUNCTION CANCELLATION LEVER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-12 ARM AND UPPERSTRUCTURE SWING LEFT-HAND CONTROL LEVER . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-12 BOOM AND BUCKET RIGHT-HAND CONTROL LEVER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-13 TRAVEL CONTROL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-14 OPTION PEDAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-15 UNLOCKING AND LOCKING OF PEDALS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-15 Unlocking . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-15 Locking . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-15 CAB LIGHT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-15 COAT HANGER HOOK . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-16 REAR RIGHT-HAND SIDE WINDOW . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-16 STORAGE COMPARTMENT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-17 STORAGE TRAY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-17 ASHTRAY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-17 CAB RADIO COMPARTMENT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-17 SPEAKER COMPARTMENTS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-17 FUSE BOX . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-17 OPERATOR'S SEAT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-18 WINDSHIELD . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-21 Opening . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-21 Closing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-21 LOWER FRONT WINDOW . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-22 WINDOW-BREAKER HAMMER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-22 AIR VENTS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-22 REAR VIEW MIRRORS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

On the cab . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

On the upperstructure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Rear . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

3-23 3-23 3-23 3-23

FUEL TANK . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-24 UPPER HOOD . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-24 Issued 10-02

Bur

6-34630NA

3-1

CHAPTER 3 - INSTRUMENTS AND CONTROLS ENGINE HOOD . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-25 WINDSHIELD WASHER RESERVOIR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-25 SIDE DOORS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-26 Left-hand rear side door . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-26 Right-hand rear side door . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-26 Right-hand front side door . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-26 LOWER PANELS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-26 TOWING POINT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-26 LOAD HANDLING EYES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-27 TOOL SUPPLY VALVES (OPTIONAL) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-28 OPTIONAL TOOL FLOW SELECTOR VALVE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-28

3-2

Issued 10-02

Bur

6-34630NA

CHAPTER 3 - INSTRUMENTS AND CONTROLS

CAB DOOR

The door can be latched in completely open position.

To unlatch the door, push the lever (3) downward.

WARNING: When seated in the operator’s compartment, with the engine running, make sure that you do not to operate the left-hand control lever inadvertently when unlocking the door. To prevent an incident, place the left-hand control arm in the raised position.

See Function cancellation lever.

3

WARNING: Be careful not to get your hand or anything caught in the door when closing it.

WARNING: Do not leave the door ajar. Fix it in a latched position.

CT02C032

Figure 3

To open the door, use the handle (1) from the outside and use the handle (2) from the inside.

1 Figure 1

CT02C030

2 CT02C031

6-34630NA

Figure 2

Issued 10-02 Bur

3-3

CHAPTER 3 - INSTRUMENTS AND CONTROLS

STEPS AND ACCESS HANDLES WARNING: Always maintain three point support while getting on and off the machine and entering or exiting the operator’s cab. A three point support system has been provided that enables a person to use simultaneously two hands and one foot or two feet and one hand while ascending, descending or moving about the machine.

WARNING: To get in or out of the cab, it is imperative that the upperstructure frame is in line with the undercarriage.

Figure 5

CT02E040

WARNING: Clean the steps and access handles and remove all traces of grease, oil, mud, and (in winter) ice.

WARNING: Never jump down from the machine. When leaving the machine or upperstructure, always face the machine and use the steps and access handles.

CT02E039

Figure 4

When getting down from or getting onto the machine, use the steps, the tracks and the access handles.

3-4

Issued 10-02

Bur

6-34630NA

CHAPTER 3 - INSTRUMENTS AND CONTROLS

POSITION OF THE OPERATOR’S COMPARTMENT CONTROLS AND ACCESSORIES 12 8

2

14

10 1

12 9 11

7 4

13

3 6 5

4

Figure 6

CT02C282

1.

2.

3.

4.

5.

6.

7.

11

OPERATOR'S SEAT FUNCTION CANCELLATION LEVER LEFT-HAND CONTROL LEVER FOOT REST (PEDAL LOCKED) LEFT-HAND TRAVEL CONTROL PEDAL AND LEVER RIGHT-HAND TRAVEL CONTROL PEDAL AND LEVER OPTION PEDALS

8.

9.

10.

11.

12.

13.

14.

INSTRUMENT PANEL HEATING, AIR-CONDITIONING, AND OPTIONAL CONTROL RIGHT-HAND CONTROL LEVER AIR VENTS RIGHT-HAND CONTROL ARM LEFT-HAND CONTROL ARM SPEAKERS

WARNING: Before starting the engine, make sure that you are fully aware of the location of and the function of each control.

Incorrect operation of the controls can cause serious injuries.

6-34630NA

Issued 10-02 Bur

3-5

CHAPTER 3 - INSTRUMENTS AND CONTROLS

RIGHT-HAND CONTROL ARM 1

2

3 4 Figure 7

CT02E041

1. INSTRUMENT PANEL For more details, see Instrument panel.

2. STARTER SWITCH This switch has four positions, ON (contact), S TA RT ( e n g i n e i g n i t i o n ) , O F F ( e n g i n e shut-down) and ACC (accessory current supply).

See Star ting the engine in the Operati ng Instructions section.

This key is also used to lock the cab door, the engine hood, the side doors, and the fuel tank cap.

3. ENGINE THROTTLE BUTTON This button enables the increase or reduction in the engine speed. For LOW IDLE position, turn the button to the left. For MAXIMUM SPEED, turn the button to the right.

If there is no change in engine speed, press and release the engine automatic idle speed selector (See item 4).

4. ENGINE IDLE SPEED SELECTOR This control enables automatic engine idle without operating the throttle button. For engine automatic idle, press and release the control and the engine will be in LOW IDLE position. Press once again on the control then release it, the engine returns to its initial speed.

3-6

Issued 10-02

Bur

6-34630NA

CHAPTER 3 - INSTRUMENTS AND CONTROLS

INSTRUMENT PANEL 1

4

2

3

5 Figure 8

CT02E041

4. OVERHEATING INDICATOR LAMP The audible warning device will sound

WARNING: The role of the instrument panel is to indicate the state of the machine and quickly warn the operator in case of any malfunction, through alarms. It should not be used for checking or maintenance.

The instrument panel is not waterproof. Make sure that it does not get wet 1. FUEL LEVEL INDICATOR

This indicator lamp shows that the engine coolant or hydraulic fluid temperature is abnormally high. Bring the engine to idle mode and reduce the water or fluid temperature. Check and clean the radiator.

135_TBD7

When the indicator needle moves closer to the E zone, fuel needs to be added in the reservoir.

The indicator functions when the key switch is in the ON position.

2. ENGINE INDICATOR

COOLANT

5. ENGINE OIL PRESSURE INDICATOR LAMP The audible warning device will sound This indicator lamps up when the engine oil pressure is too low. If the indicator lamps up during operation, move the machine to a safe location, lower the attachment to the ground, shut down the engine, remove the ignition key and determine the source of the malfunction.

TEMPERATURE

This indicator is divided into two zones: white zone, normal operating temperature and red zone: hot. The indicator functions when the key switch is in the ON position.

IMPORTANT: If the needle is in the red zone, move the machine to a safe location, lower the attachment to the ground, shut down the engine, remove the ignition key and check the cooling system to determine the source of the malfunction.

Figure 9

135_TBD8

Figure 10

3. HOURMETER The hourmeter enables service operations to be scheduled. Its indications are similar to those of a watch when the engine is running. Its operation is indicated by the blinking of a green indicator lamp. See section Servicing intervals.

6-34630NA

Issued 10-02 Bur

3-7

CHAPTER 3 - INSTRUMENTS AND CONTROLS

6

7

8

9

10

11

12

13 Figure 11

CT02C046

6. FUEL LEVEL INDICATOR LAMP The audible warning device will sound

9. PREHEATING INDICATOR LAMP The audible warning device will sound

This indicator lamps up when the fuel level in the reservoir is too low, fuel must be added as soon as possible.

This indicator lamps up when the key switch is in the ON position and the temperature is low. Wait for the indicator lamp to go off before starting the engine.

IMPORTANT: Do not wait until the fuel tank is completely empty before refilling or it will be necessary to bleed the fuel circuit.

135_TBD9

Figure 12

7. BATTERY CHARGE INDICATOR LAMP The audible warning device will sound This indicator lamps up when the alternator/fan belt is broken or when the alternator is not charging the battery any more. If the indicator lamps up during operation, move the machine to a safe location, lower the attachment to the ground, shut down the engine, remove the ignition key and determine the source of the malfunction.

135_TBD10

Figure 15

135_TBD12

10. Windshield wiper switch See Windshield wiper switch for its use.

11. Windshield washer switch See Windshield washer switch for its use.

12. Working light switch See Working light switch for its use.

13. High speed travel switch.

See High speed travel switch for its use.

Figure 13

8. ENGINE ELECTRIC CIRCUIT INDICATOR LAMP The audible warning device will sound This indicator lamps up in case of failure of the engine electric circuit (short-circuit or disconnection). Check the electric circuits of the engine.

135_TBD11

3-8

Figure 14

Issued 10-02

Bur

6-34630NA

CHAPTER 3 - INSTRUMENTS AND CONTROLS

LEFT-HAND CONTROL ARM

2

3

4

5 6 1 Figure 16

CT02C047

1. HORN To sound the hor n, press at the end of the left-hand control lever.

IMPORTANT: Always sound the horn before operating the machine.

2. FUNCTION CANCELLATION LEVER The shape of the function cancellation lever was designed to prevent the operator from leaving the operator’s compar tment without having raised the lever beforehand. See function cancellation lever.

IMPORTANT: This switch should only be used in case of an emergency. Do not use it on a day-to-day basis.

5. HEATING AND VENTILATION CONTROL See Heating and ventilation control for its use.

6. HEATING, VENTILATION OR AIR-CONDITIONING CONTROL (Optional) See Heating, ventilation or air-conditioning control for its use.

WARNING: To access or exit the operator’s compartment, the function cancellation lever must be in the raised position. Never try to avoid this basic requirement.

3. OPTION CONTROL (Optional) This two-position switch enables the activation of options such as the hydraulic breaker, grab, shears, etc. Place the switch in one of the two positions depending on the accessories to be used. See Auxiliary hydraulic systems in the Operating Instructions section.

4. EMERGENCY SHUT DOWN SWITCH This switch shuts down of the engine in case of an emergency. See Shutting down the engine in the Operating Instructions section.

6-34630NA

Issued 10-02 Bur

3-9

CHAPTER 3 - INSTRUMENTS AND CONTROLS

WORKING LIGHT SWITCH

WINDSHIELD WIPER SWITCH

Figure 19

CT02C055 CT02C053

Figure 17

This switch switches the working lights on or off.

Press the button, the instrument panel as well as the working lights comes on. Press the button again to switch them off.

WINDSHIELD WASHER SWITCH

T hi s swi tc h ha s t hr e e po si ti on s : Sh ut d own , Intermittent and Continuous. Press the switch for intermittent operation of the windshield wiper, the lamp (I) comes on. Press the switch again to obtain continuous operation of the windshield wiper, the lamp (II) comes on. Press the switch once more for the function to cease.

Do not operate the windshield wiper if the windshield is dry, as this may damage the windshield wiper.

HIGH SPEED TRAVEL SWITCH

CT02C054

Figure 18

Press and hold the switch for the windshield washer and the windshield wiper to function, release the switch to stop this operation.

CT02C056

Never operate the windshield washer when the reservoir is empty, as this may damage the electric pump.

When the switch is pressed, the travel speed goes from low to high. A red indicator lamps up when the travel is in high speed mode.

Figure 20

When the engine is star ted, low speed is automatically selected.

WARNING: If the travel speed is changed during travel, the machine may veer off course. Shut down the machine before changing speeds.

Low speed: Suited for travel on a slope or on difficult terrain.

High speed: Suited for travel on level ground.

As soon as the travel load becomes too great, the machine automatically returns to low speed.

3-10

Issued 10-02

Bur

6-34630NA

CHAPTER 3 - INSTRUMENTS AND CONTROLS

HEATING, VENTILATION AND AIR-CONDITIONING CONTROL 5

2

3

7

6

4

1 Figure 21

CT02D158

1. ON/OFF This push button (1) is for turning the system on or off.

When the system is turned on it will operate at the same setting as selected for previous use.

2. AIR-CONDITIONING SWITCH This switch (2) turns the air-conditioning on/off.

When it is on, the indicator lamp on the switch comes on.

3. VENTILATION

To select the type of air flow, press the button (5) relating to the type of air flow desired. Depending on the selected type, a built-in indicator lamp comes on.

6. WINDSHIELD DEFROSTER This button (6) allows the windshield to be d e f r o s t e d . P r e s s t h e bu t t o n , w i n d s h i e l d defrosting is carried out and a built-in indicator lamp comes on. To stop, press the button again, the indicator lamp goes off.

7. AIR RECYCLING

These push buttons (3) allows the air flow to be increased or reduced. To increase the flow of air, press the top button. To decrease the flow of air, press the lower button. The segments increase or reduce depending on the flow selected.

4. TEMPERATURE These push buttons (4) help increase or reduce the temperature. To increase the temperature, press the Right-Hand button. To decrease the temperature, press the Left-Hand button. The temperature is controlled by the increase or reduction in the number of segments.

This button (7) allows two different types of air circulation to be selected: External air circulation.

Internal air circulation.

Each time the button is pressed, the type of circulation will be changed. Depending on the selected type, a built-in indicator lamp comes on.

5. AIR FLOW DIRECTION These push buttons (5) are used for the selection of three types of air flow direction: Via the top front air vent.

Via the top front and rear air vents.

Via the top and lower rear air vents.

6-34630NA

Issued 10-02 Bur

3-11

CHAPTER 3 - INSTRUMENTS AND CONTROLS

FUNCTION CANCELLATION LEVER The shape of thefunction cancellation lever was designed to prevent the operator from leaving the operator’s compartment without having raised the lever beforehand.

The function cancellation lever cancels the hydraulic controls.

In the raised position, all hydraulic controls are stopped.

ARM AND UPPERSTRUCTURE SWING LEFT-HAND CONTROL LEVER The speed of movement of the ar m or the upperstructure swing depends on the control lever tilt angle. In the intermediate position both movements can be obtained simultaneously.

1. The arm extends.

2. The arm retracts.

3. The upperstructure turns towards the left.

4. The upperstructure turns towards the right.

NOTE: The movements of the machine are shown in the Control functions decal. See Decals.

1

3

CT02C037

4

Figure 22

2

The left-hand control ar m is raised along with thefunction cancellation lever for better access.

Figure 24

CT02C039

4

3

2

CT02C038

1

Figure 23

In the lowered position, all hydraulic controls are operational.

Figure 25

CS98M554

WARNING: To access or exit the operator’s compartment, the function cancellation lever must be in the raised position. Never forget this basic requirement.

3-12

Issued 10-02

Bur

6-34630NA

CHAPTER 3 - INSTRUMENTS AND CONTROLS

BOOM AND BUCKET RIGHT-HAND CONTROL LEVER The speed of movement of the boom or the tool depends on the control lever tilt angle. In the inter mediate position both movements can be obtained simultaneously.

5. The boom lowers.

6. The boom raises.

7. The bucket retracts (filling).

8. The bucket extends (dumping).

NOTE: The movements of the machine are shown in the Control functions decal. See Decals.

5

7

8

6 Figure 26

CT02C040

6

5 7

8

Figure 27

CS98M554

6-34630NA

Issued 10-02 Bur

3-13

CHAPTER 3 - INSTRUMENTS AND CONTROLS

TRAVEL CONTROL Travel control is done by using the levers or the pedals. To travel in a straight line, both levers have to be simultaneously operated, either forward or backward. Change of direction is done either by o p e r a t i n g a s i n g l e l ev e r, o r b y o p e r a t i n g simultaneously one lever forward and the other backward, so that the machine pivots on the spot.

See Moving the machine in the Operating Instructions section.

IMPORTANT: In the normal travel position, the operator's compartment is above the idler wheels and the travel reduction gears are to the rear of the upperstructure. If the upperstructure is turned 180 degrees in relation to the undercarriage, to move the machine forward, the levers have to be pulled towards yourself (i.e. in reverse) and vice-versa.

9

10

12 Figure 28

CT02C063

9

11

10

12

NOTE: The forward or reverse travel speed depends on whether the high speed travel switch is used or not. See High speed travel switch.

NOTE: The movements of the machine are shown in the Control functions decal. See Decals.

11

9. The left-hand track moves forward.

10. The left-hand track moves backward.

11. The right-hand track moves backward.

Figure 29

CS98M544

12. The right-hand track moves forward.

3-14

Issued 10-02

Bur

6-34630NA

CHAPTER 3 - INSTRUMENTS AND CONTROLS

OPTION PEDAL

UNLOCKING AND LOCKING OF PEDALS IMPORTANT: The pedal must be locked into position shown in figure 35 to have the hydraulics in neutral.

UNLOCKING Push the locking pin forward.

Figure 30

BD02D164

This pedal is used for options such as a hydraulic breaker.

WARNING: This pedal has to be locked when the option is not used.

CT02C044

Figure 31

LOCKING Pull the locking pin into the pedal notch as shown.

CT02C045

Figure 32 Figure 33

CAB LIGHT Located on top of the cab on the left-hand side, the lighting is controlled by a switch built into the lamp bracket.

NOTE: To replace bulbs, see Replacing a bulb in the Electrical system section.

6-34630NA

Issued 10-02 Bur

3-15

CHAPTER 3 - INSTRUMENTS AND CONTROLS

CT02C058

Figure 34

Figure 37

CT02C061

COAT HANGER HOOK The coat hanger hook is located on the rear left-hand cab upright.

CT02C059

Figure 35

REAR RIGHT-HAND SIDE WINDOW To open the window, pull the handle backwards.

CT02C060

Figure 36

To close the window, bring the handle back towards the inside of the cab.

3-16

Issued 10-02

Bur

6-34630NA

CHAPTER 3 - INSTRUMENTS AND CONTROLS

STORAGE COMPARTMENT

CAB RADIO COMPARTMENT

The glove compartment is located on the right-hand side in front of the cab.

Located on the rear right-hand side of the seat is a car type radio. For operating instructions see the radio manual provided by the manufacturer.

SPEAKER COMPARTMENTS Located behind the cab, these compartments are designed for installing speakers.

Figure 38

CT02C068

STORAGE TRAY The storage tray is located behind the operator’s seat.

CT02C073

Figure 41

FUSE BOX The fuse box is located on the rear right-hand side of the cab.

NOTE: To replace a fuse, see Fuses in the Electrical system section.

Figure 39

CT02C069

ASHTRAY The ashtray is located on the right-hand side in front of the cab.

CT02C074

Figure 40

CT02C070

6-34630NA

Figure 42

Issued 10-02 Bur

3-17

CHAPTER 3 - INSTRUMENTS AND CONTROLS

OPERATOR'S SEAT

8

7 7

9

4 1 3

5

2

6 Figure 43

CT02C075

1. SUSPENSION ADJUSTMENT 2. FORE/AFT ADJUSTMENT 3. SEAT POSITION ADJUSTMENT

4. SEAT BACK ANGLE ADJUSTMENT 5. LUMBAR SUPPORT ADJUSTMENT 6. CONSOLE AND SEAT ADJUSTMENT

In order to operate the machine correctly and with maximum efficiency and comfort, adjust the seat to suit the weight and size of the operator.

3-18

7. ARMREST ANGLE ADJUSTMENT 8. HEADREST 9. SEAT BELT

NOTE: The adjustment of the seat can be done correctly only when the operator is seated in the seat and the engine is shut down.

Issued 10-02

Bur

6-34630NA

CHAPTER 3 - INSTRUMENTS AND CONTROLS 1. Suspension adjustment The adjustment can be done from 50 to 120 kg (110 to 264 lb). Turn the switch (1) in the + or direction.

1 3

Figure 46

CT02C078

4. Seat back angle adjustment

Figure 44

CT02C076

To adjust the seat back angle, hold the lever (4) in raised position. Move with the seat back to the desired position and then release the lever.

2. Forward/reverse position adjustment

WARNING: Before tilting the seat back it is essential for the armrests to be in raised position to prevent them from fouling the control levers.

Hold the control (2) in raised position, slide the seat to the required position and then release the control.

4

2

Figure 45

CT02C077

3. Seat plate adjustment To raise or lower the front of the seat, hold the lever (3) in raised position. Move with the seat to the desired position and then release the lever.

To raise or lower the rear of the seat, hold the lever (3) in lowered position. Move with the seat to the desired position and then release the lever.

5. Lumbar support adjustment Use the inflation bulb (5) to inflate the lumbar suppor t. Press the button on the tip of the inflation bulb (5) to deflate the lumbar support.

5

CT02C080

6-34630NA

Issued 10-02 Bur

Figure 47

CT02C079

Figure 48

3-19

CHAPTER 3 - INSTRUMENTS AND CONTROLS 6. Console and seat adjustment Pull the lever (6) upwards, and slide the seat and control arm assembly to the desired position, then release the lever.

8

Figure 51

CT02C083

7. Safety belt

6

Sit comfortably on the seat, pull the seat belt out then engage it in the kink system (9).

Figure 49

CT02C081

7 - Armrest angle adjustment Lift the armrests, turn the knob (7) to get the desired angle then lower the armrest.

If the section of belt pulled out is not long enough, release it, so it rolls up and then pull it out again.

To fasten the seat belt, insert the buckle in the slide closing of the opposite belt. To unfasten the seat belt, lift the slide closing of the opposite belt.

WARNING: Always fasten your safety belt before starting the engine. The safety belt will protect you effectively if you fasten it correctly and wear it at all times. The safety belt should not be too loose. It should not be twisted or caught in the seat.

7

To release the seat belt, press down on the releasing lever (9).

CT02C082

Figure 50

8 - Headrest adjustment The headrest (8) can be adjusted upwards and downwards and backwards and forwards.

IMPORTANT: Inspect the seat belt. Make sure that it is not damaged, that the mounting screws are correctly tightened and replace any defective parts.

The seat belt must be kept clean. Use only soap and water to clean the belt, do not use bleach or dies.

NOTE: To make the headrest return to its initial position (to the rear), tilt it completely forwards and then release it.

9

CT02C084

3-20

Figure 52

Issued 10-02

Bur

6-34630NA

CHAPTER 3 - INSTRUMENTS AND CONTROLS

WINDSHIELD

3. Engage the right-hand latch (5) in the cab upright.

WARNING: Make sure you follow the instructions below properly. If the windshield is not handled correctly it could slip and injure your fingers or hand.

OPENING 1. Fold back the sunshield, if equipped (1) against the windshield and pull the lever (2).

2

5

Figure 56

CT02C088

CLOSING 1. Unlock the right-hand latch (5) of the cab upright

1 Figure 53

CT02C071

2. Hold the upper (3) and lower (4) handles and carefully raise the windshield. Push to the rear until it engages.

5 Figure 57

CT02C089

2. Hold the lower (4) and upper (3) handles and carefully lower the windshield. Make sure the window is completely down.

3

4 Figure 54

CT02C086

4 CT02C090

CT02C087

6-34630NA

Figure 58

Figure 55 Issued 10-02 Bur

3-21

CHAPTER 3 - INSTRUMENTS AND CONTROLS

3

CT02C086

Figure 59

Make sure the top of the windshield is correctly latched.

Figure 62

CT02C093

WINDOW-BREAKER HAMMER Located on the right-hand cab upright, the window-breaker hammer is to be used to break the rear window in case of an emergency.

CT02C091

Figure 60

LOWER FRONT WINDOW The lower front window may only be removed when the windshield is open.

1. Pull the window upwards to remove it.

Figure 63

CT02C094

AIR VENTS The air vents (1) are located to the front and rear as well as under the operator's compartment, and allow the circulation and direction of air to be controlled.

The air vents are opened and controlled manually.

NOTE: The air vents must always be open when the air conditioning is in use.

CT02C092

1

Figure 61

2. Place the window in the storage position provided to the left of the operator's seat and then engage it correctly.

CT02C095

3-22

Figure 64 Issued 10-02

Bur

6-34630NA

CHAPTER 3 - INSTRUMENTS AND CONTROLS ON THE UPPERSTRUCTURE

1

Figure 65

CT02C085

CT02C100

Figure 68

REAR

1 Figure 66

CT02C096

REAR VIEW MIRRORS Before any travel operation, make sure that the rear view mirrors are correctly adjusted.

CT02C101

Figure 69

ON THE CAB

CT02C097

6-34630NA

Figure 67

Issued 10-02 Bur

3-23

CHAPTER 3 - INSTRUMENTS AND CONTROLS

FUEL TANK

UPPER HOOD

NOTE: Clean around the fuel cap before refuelling and do not remove the filter located in the filler orifice.

See Fuel tank filter in the Maintenance/Adjustments section.

This hood gives access to the hydraulic tank .

To open it, pull the handle.

NOTE: In cold weather, use fuel corresponding to the ambient temperature. See Ingredients in the Lubrication/Filters/Fluids section.

IMPORTANT: In cold weather, fill the fuel tank after each working day to prevent the formation of condensation.

WARNING: Never refuel when the engine is running. Never smoke when refuelling.

Capacity of the reservoir: 265 litres (70 gal).

Located on the right-hand side of the machine.

When installing the fuel cap, make sure that it is correctly placed in the notches and then lock it by turning it up against the stop.

Figure 71

CT02E056

Lift the hood to the maximum so that it gets locked with the supporting prop. (Figure 72)

NOTE: Use the key switch to lock the fuel cap.

Figure 72

CT02E057

To close, operate the screw of the supporting prop then pull down and close the hood.

CT02E053

3-24

Figure 70

Issued 10-02

Bur

6-34630NA

CHAPTER 3 - INSTRUMENTS AND CONTROLS

ENGINE HOOD

WINDSHIELD WASHER RESERVOIR

To open, pull the handle and lift the hood.

Located under the upper hood, this reservoir is equipped with an electric pump controlled by the windshield wiper, windshield washer control.

Figure 73

CT02E054

Lift the hood to the maximum so that it gets locked with the support strut.

Figure 74

CT02E059

To cl os e, li ft t he ho od sl ig htl y, pu ll ba ck th e supporting strut, then lower the hood and close it.

Use the switch key to lock the hood.

6-34630NA

Issued 10-02 Bur

3-25

CHAPTER 3 - INSTRUMENTS AND CONTROLS

SIDE DOORS

TOWING POINT Located behind the undercarriage.

LEFT-HAND REAR SIDE DOOR This door gives access mainly to the batteries, the air filter, etc.

This point is to be used for towing the machine, see To w i n g t h e m a c h i n e i n s e c t i o n O p e r a t i n g instructions.

Use the outside handle to open the doors. To hold the doors, open, remove the struts from their storage position and install them in the holes provided. When closing, put the struts back into storage position.

Make sure that the slings, chains and accessories are in perfect condition and can bear the load to be moved.

WARNING: Towing is a delicate operation which is always carried out at the risk of the user. The manufacturer's warranty does not apply to incidents or accidents, which occur during towing.

RIGHT-HAND REAR SIDE DOOR The door gives access to a number of hydraulic components (filters, etc.).

RIGHT-HAND FRONT SIDE DOOR The door gives access to a number of components (fuel filter, windshield washer reservoir, etc.).

WARNING: It is forbidden to use this point for towing another vehicle.

WARNING: Always install the struts when the doors are open.

WARNING: The machine must be towed very slowly, over a short distance and only if it is really unavoidable.

WARNING: Before undertaking any travel, make sure the side doors are properly closed.

LOWER PANELS

Figure 76

CT02C183

CT02E064

Figure 75

Located under the upperstructure, these panels give access to several machine components.

IMPORTANT: Do not operate the machine if the panels have been removed.

3-26

Issued 10-02

Bur

6-34630NA

CHAPTER 3 - INSTRUMENTS AND CONTROLS

LOAD HANDLING EYES When lifting loads, the slings and chains must be attached to the load handling eye on the bucket.

IMPORTANT: This attachment point will only carry the load indicated in the maximum lift capacities table. See Maximum lift capacities tables in the Operating Instructions section.

WARNING: Never weld hooks or lugs on the bottom plate of the bucket for handling operations. The only attachment point which may be used is the bucket eye.

Figure 77

CT02C184

6-34630NA

Issued 10-02 Bur

3-27

CHAPTER 3 - INSTRUMENTS AND CONTROLS

TOOL SUPPLY VALVES (OPTIONAL) Located at the end on both sides of the arm, these valves feed optional tools such as the hydraulic breaker, etc. These valves have two positions: open/closed.

CT02E067

CT02E066

OPTIONAL TOOL FLOW SELECTOR VALVE This valve is used to select the type of flow to be used depending on the tool installed on the machine.

IMPORTANT: Consult your CASE Dealer before mounting optional tools.

Figure 78

CT02C186

Figure 80

CT02E068

Figure 81

Figure 79

To access the valve, remove the upper plate.

3-28

Issued 10-02

Bur

6-34630NA

CHAPTER 4 - OPERATING INSTRUCTIONS

Chapter 4 OPERATING INSTRUCTIONS TABLE OF CONTENTS BEFORE OPERATING THE MACHINE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-3 OPERATING THE MACHINE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-3 RUN-IN PERIOD . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-4 After the First 50 Hours . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-4 After the First 250 Hours . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-4 STARTING THE ENGINE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-5 BRINGING THE MACHINE UP TO OPERATING TEMPERATURE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-6 Hydraulic Fluid Warm-up . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-7 ENGINE OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-8 STOPPING THE ENGINE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-8 In the Event of An Emergency . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-9 OPERATING THE MACHINE IN COLD WEATHER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Battery . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Fuel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Engine Oil . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Hydraulic Fluid . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Coolant Solution . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

4-9 4-9 4-9 4-9 4-9 4-9

OPERATING THE MACHINE IN HOT WEATHER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-10 OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-10 MACHINE TRAVEL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-11 TRANSPORTING THE MACHINE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-13

By Rail . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-13 On a Trailer . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-13 Unloading . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-15 HANDLING THE MACHINE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-16 OPERATING THE MACHINE IN WATER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-16 PARKING THE MACHINE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-16 OPERATING THE MACHINE ON SLOPING GROUND . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-17 TOWING THE MACHINE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-17 OPERATING THE BUCKET . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-18 Filling . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-18 Excavating method . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-18 LOWERING THE ATTACHMENT IN THE EVENT OF A MACHINE FAILURE . . . . . . . . . . . . . . . . . . . . . . . . . 4-19 MACHINE STORAGE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-20 Preparation for storage . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-20 Periodical checks . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-20 Starting up after storage . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-21

Issued 10-02

Bur

6-34630NA

4-1

CHAPTER 4 - OPERATING INSTRUCTIONS

4-2

Issued 10-02

Bur

6-34630NA

CHAPTER 4 - OPERATING INSTRUCTIONS

BEFORE OPERATING THE MACHINE WARNING: Do not attempt to operate this machine unless you have first read and perfectly understood the safety messages and instructions appearing in this manual.

Before operating this machine, be sure to do the following: 1. Check the level of all fluids (engine oil, hydraulic fluid and coolant) and make sure that the fluids and lub r i ca nts ar e s uita bl e for pr evai lin g conditions. See Ingredients in the Lubrication/Filters/Fluids section and Operating the machine in cold weather.

2. Carry out the daily maintenance operations. See section Servicing intervals.

3. Inspect the machine, look for any signs of possible leakage and check the hoses. Tighten o r r e p l a c e a s n e c e s s a r y. S e e s e c t i o n Maintenance/Adjustments.

4. See Run-in period if the machine is new or if the engine has been reconditioned.

5. Check the track assemblies. See Tracks in the Maintenance/Adjustments section.

6. Clean the steps and access handles. Grease, oil, mud or ice (in winter) on the steps and access handles can causes accidents. Make sure they are kept clean at all times.

7. Clean or replace any decals which are illegible.

See Decals in the Safety/Decals/Hand signals section.

8. Make sure that the engine hood and the side doors are properly closed and latched.

9. Secure the cab door in either fully closed or fully opened position.

10. Remove any obstructions which hinder visibility.

Clean the windshield, the windows and the rear view mirrors.

11. Check that no tools or other items have been left on the machine (be it on the undercarriage or the upperstructure) or in the operator's compartment.

12. Make sure nobody is on or under the machine.

The operator must be alone on the machine.

13. Make sure nobody is standing in the machine working area.

14. Find out about current safety measures in use on the work site.

15. Work out a convenient means of escape from the machine (emergency exit via the windshield, the rear window glass) in the event of the cab door being jammed or the machine turning over. See Windshield in the Controls/Instruments/Accessories section.

16. Before undertaking any travel or working operations during hours of darkness, make sure the lighting and signalling equipment is fully operative.

OPERATING THE MACHINE WARNING: Check all controls and safety devices in a safe, open area before starting work.

When operating the machine, be sure to do the following: 1. When starting the engine, be sure to use the correct procedure for the prevailing weather conditions. See Starting the engine.

2. Regularly consult the hourmeter to ensure that all ser vicing operations are carried out punctually. See section Servicing intervals.

3. If you use your machine in particularly harsh conditions (dusty or corrosive atmosphere), the ser vicing inter vals should be reduced accordingly.

4. Take note of the locations of pipes/cables before starting work.

5. Do not work near overhead high-voltage electric lines without checking beforehand that all necessary measures have been taken to respect the safest distances: Less than 57 000 volts: 3 metres ( 10 ft) More than 57 000 volts: 5 metres (16 ft) 6. When working on a public highway, use standard traffic signs and take into consideration the working range of the upperstructure and its attachments. Local regulations stipulate the number, type and location of reflector strips.

7. Never operate the working or travel controls unless you are properly seated in the operator's seat with the seat belt correctly fastened.

8. Modify your driving to suit the type of work and working conditions. See Operating instructions in the Job Site Operation section.

9. Do not allow anyone within the machine's operating radius. Stop all operations until everyone has moved away.

10. Operate all controls gradually to ensure smooth machine operation.

6-34630NA

Issued 10-02 Bur

4-3

CHAPTER 4 - OPERATING INSTRUCTIONS 11. See Operating in water if the machine will be standing in water during use.

12. See Transporting the machine when driving the machine onto a trailer.

13. See Handling the machine when it is necessary to lift the machine.

14. In some configurations, the working range of the attachment allows the tool to interfere with the machine. Always maintain a safe minimum distance between the tool and the machine.

15. Never use the attachment for sweeping the ground to level out r ubble or push objects (transversal stress on the attachment).

16. Avoid running the engine in a confined space. If there is no alternative, proper ventilation must be provided at all times.

17. Dust, smoke or mist can reduce visibility and cause an accident. Reduce speed or come to a complete halt until visibility has improved.

18. In the event of an operation problem or failure, move the machine to a safe place, lower the attachment to the ground, shut down the engine and remove the starter switch key. Locate the problem, report it if necessary and take the necessary steps to warn others not to attempt to operate the machine.

19. Do not stop the engine without taking prevailing weather conditions into consideration. See Stopping the engine.

20. See Parking the machine when you have to park the machine.

21. Whenever load handling operations are to be carried out, it is imperative to adhere strictly to the instructions given in this manual and local legislation. See Load handling.

During the run-in period, the following checks and servicing operations should be carried out in addition to those specified in the service schedule: AFTER THE FIRST 50 HOURS Replace the pilot circuit filter and the return filter. See Hydraulic system in the Lubrication/Filters/Fluids section.

Check that the shoe bolts are tightened to the correct torque. See Tracks in the Maintenance/Adjustments section.

Check all nuts and screws are tightened to the correct torque. See Hardware torque inspection in the Maintenance/Adjustments section.

AFTER THE FIRST 250 HOURS Change the oil in the travel reduction gears. See Tr a v e l reduction gears in the Lubrication/Filters/Fluids section.

HYDRAULIC FLUID WARM-UP Turn the engine throttle button to half-open position.

Operate the bucket control slowly until the bucket is completely closed. Operate the arm retracting control slowly until the arm is completely retracted and hold the control in this position for 30 seconds. During this time the temperature of the hydraulic fluid will increase.

After 30 seconds, extend the arm completely and hold the control in this position a further 30 seconds.

Repeat this operation of retraction and extension of the arm until the temperature increases.

Operate the travel and attachment controls three or four times to activate hydraulic fluid circulation.

22. When travelling with the hydraulic breaker (optional), make sure it is not too close and not pointing in the direction of the cab.

RUN-IN PERIOD Your machine will last longer and will give better and more economical performance if you pay particular attention to the engine during the first twenty hours of operation.

During this period: Warm up the engine before using it under load.

Do not run the engine for a long period at idle speed.

Frequently check the instruments on the instrument panel.

Check the oil levels and coolant solution level frequently.

4-4

Issued 10-02

Bur

6-34630NA

CHAPTER 4 - OPERATING INSTRUCTIONS

STARTING THE ENGINE NOTE: If the machine has been out of use for some time, see Starting up after storage in the Storage section.

NOTE: If you need to start the engine using a booster battery, see Connecting a booster battery in the Electrical system section.

1. Take up position correctly in the operator's seat with the seat belt correctly fastened. See Operator's seat in the Controls/Instruments/Accessories section.

2. Make sure that the control function cancellation lever is in the raised position.

Sound the horn before starting the engine.

CT02C189

Figure 3

5. Turn the starter switch key to the ON position and hold it there. The preheating indicator lamp comes on.

IMPORTANT: Do not keep the starter switch key in the preheating position for more than 6 seconds.

Figure 1

CT02C037

3. Make sure the engine throttle button is in low idle position. In cold weather, leave it in half-way position.

CT02D268

Figure 4

6. Turn the starter switch key to the START position. Release the key as soon as the engine starts to turn. If the engine stops, wait about a minute and recommence the operation.

IMPORTANT: Do not operate the starter motor for more than 20 seconds at one time. Do not operate the starter motor when the engine is running.

IMPORTANT: When the engine is running, let it heat up until the low idle mode is steady.

Figure 2

CT02C188

IMPORTANT: When the engine is running, check the indicators and lights on the instrument panel regularly.

4. Insert the starter swich key then turn the key to the ACC position, the red indicator lamps on the instrument panel remain illuminated. The audible alarm device will sound.

6-34630NA

Issued 10-02 Bur

4-5

CHAPTER 4 - OPERATING INSTRUCTIONS

BRINGING THE MACHINE UP TO OPERATING TEMPERATURE IMPORTANT: Normal operating temperature of the hydraulic fluid is between 50°C and 80°C (122° 176° F) in the middle of the temperature indicator. If the machine is used with the hydraulic fluid at a temperature below 20°C (68° F) then damage can be caused.

After star ting the engine and before using the machine, wait till the temperature of the hydraulic fluid reaches 20°C (68° F).

CT02C191

Figure 5

7. Lower the function cancellation lever.

Figure 7

CT02C193

CT02C192

Figure 6

With the engine throttle button a quarter open, start the engine and allow it to run approximately for 5 to 10 minutes. When the coolant temperature increases, carry out the hydraulic fluid warm-up procedure.

Figure 8

CT02C188

4-6

Issued 10-02

Bur

6-34630NA

CHAPTER 4 - OPERATING INSTRUCTIONS

ENGINE OPERATION

STOPPING THE ENGINE

When the engine has started and before beginning work, the following procedure must be observed:

1. Turn the engine throttle button to low idle position and let the engine run for a minute or so.

1. Let the engine idle for about five minutes until it has warmed up.

IMPORTANT: In cold weather, let the engine run for about five minutes at idle speed.

2. Move the engine throttle button to the maximum speed position.

IMPORTANT: Always let the engine run at idle before switching off completely, except in emergency situations.

Once nor mal operating temperature has been reached, check the following: 1. The exhaust smoke is normal.

2. There is no abnormal noise or vibration.

3. There are no oil, fuel or water leaks.

The engine should be r un at full speed when operating conditions permit.

The operating speed of the machine and of the attachment should be controlled by means of the control levers.

Check the indicators and lamps on the instrument panel regularly.

CT02C194

IMPORTANT: Stop the engine immediately if one of the following situations occurs: 1. Sudden increase or decrease in engine speed.

2. Abnormal noise.

Figure 9

2. Turn the starter switch key to the OFF position.

IMPORTANT: When the engine is to be shut down for a considerable length of time, see Parking the Machine.

3. Black smoke at the exhaust.

4. Lighting up of oil pressure, battery, engine electrical circuit (if equipped) indicator lamps on the instrument panel during operation.

5. Lighting up of the overheating indicator lamp on the instrument panel during operation.

CT02C195

6-34630NA

Issued 10-02 Bur

Figure 10

4-7

CHAPTER 4 - OPERATING INSTRUCTIONS IN THE EVENT OF AN EMERGENCY In case of an emergency or when it is not possible to shut down the engine using the starter switch key, press the emergency STOP switch located on the left-hand control arm.

The engine shuts down, the audible alarm device sounds and the engine oil pressure, battery charge and engine electrical circuit indicators light up. Bring the starter switch key back to the OFF position.

To restart the engine, press again on the STOP switch then turn the starter switch key.

This switch should only be used in case of an emergency. Do not use it on a day-to-day basis.

OPERATING THE MACHINE IN COLD WEATHER Follow these recommendations: BATTERY It must be fully charged.

FUEL 1. To prevent condensation forming and water getting into the fuel system, fill the fuel tank after each day's work and drain off any water before starting the next day's work.

2. To prevent crystals forming at -2°C (28 ° F), use fuel which is rated for the ambient temperature or add an appropriate antifreeze to the fuel. See Ingredients in the Lubrication/Filters/Fluids section.

ENGINE OIL It should be of the right viscosity for the ambient temperature. See Ingredients in the Lubrication/Filters/Fluids section.

HYDRAULIC FLUID

CT02C225

Figure 11

The viscosity must correspond to the ambient temperature conditions. See Ingredients in the Lubrication/Filters/Fluids section.

COOLANT SOLUTION It should be suitable for the ambient temperature and contain a minimum of 50% ethylene glycol solution.

See Ingredients in the Lubrication/Filters/Fluids section.

4-8

Issued 10-02

Bur

6-34630NA

CHAPTER 4 - OPERATING INSTRUCTIONS

OPERATING THE MACHINE IN HOT WEATHER 1. Follow the recommendations made below: 2. Keep the coolant at the correct level in the coolant reservoir and in the radiator.

3. Use the correct solution of ethylene glycol and water in the cooling system.

4. Test the radiator cap before hot weather starts.

Replace the cap as required.

5. Clean all dirt and debris from the radiator, cooler and engine area.

6. Check the condition of the fan drive belt.

7. Check the dust valve in the air cleaner frequently during extreme dust conditions.

8. Use lubricants of the correct viscosity. See Fluids and lubricants in the Lubrication, Filters, and Fluids Chapter.

6-34630NA

Issued 10-02 Bur

BASIC OPERATION 1. Take up position in the operator's seat and adjust it so that all the controls are readily accessible.

See Operator's seat in the Controls/Instruments/Accessories section. Then fasten your safety belt.

2. Make sure the cab door is firmly latched in open or closed position.

3. Sound the horn.

4. Start the engine, taking into consideration the prevailing weather conditions. See Starting the engine.

5. Check all instruments are operating correctly.

6. Lower the function cancellation lever.

7. Try out all the controls in a safe, open area.

4-9

CHAPTER 4 - OPERATING INSTRUCTIONS

MACHINE TRAVEL WARNING: In the normal travel position, the operator's compartment is above the idler wheels and the travel reduction gears are to the rear of the upperstructure. If the upperstructure is turned 180 degrees in relation to the undercarriage, the controls are reversed.

NOTE: Travel speed depends on the tilting angle of the levers and the travel mode speed selected. See High Speed Travel Switch in Instruments and Controls.

4. Turning to the right (Forward Travel)

1. Straight line travel (Forward Travel) Press the two pedals (or push the two levers) forwards at the same time.

CS98M546

Figure 12

2. Straight line travel (Reverse Travel) Press the two pedals (or push the two levers) rearwards at the same time.

CS98M547

Figure 13

3. Turning to the left (Forward Travel) Si mpl y p res s the r igh t-ha nd p edal or th e right-hand lever forwards.

4-10

Figure 14

CS98M548

Simply press the left-hand pedal or the left-hand lever forwards.

Figure 15

CS98M551

5. Turning to the left (Reverse Travel) Si mpl y pre ss the r igh t-h and pedal or th e right-hand lever rearwards.

Figure 16

CS98M549

6. Turning to the right (Reverse Travel) Simply press the left-hand pedal or the left-hand lever rearwards.

Issued 10-02

Bur

6-34630NA

CHAPTER 4 - OPERATING INSTRUCTIONS Press one of the pedals or one of the levers and, at the same time, press the other pedal or the other lever in the same direction, but slightly harder.

Stopping travel To come to a complete halt, simply release the levers or pedals and they will return to neutral.

Figure 17

CS98M550

7. Turning on the spot, to the right Press the left-hand pedal or the left-hand lever fo rwar ds a nd a t th e s ame tim e p re ss th e r i g h t - h a n d p e d a l o r t h e r i g h t - h a n d l eve r rearwards.

CS98M545

Figure 20

Figure 18

CS98M552

8. Turning on the spot, to the left Press the right-hand pedal or the right-hand lever fo rwar ds a nd a t th e s ame tim e p re ss th e left-hand pedal or the left-hand lever rearwards.

IMPORTANT: Turning on the spot cannot be done if high speed travel is selected.

Figure 19

CS98M553

9. Gradual turn on the move

6-34630NA

Issued 10-02 Bur

4-11

CHAPTER 4 - OPERATING INSTRUCTIONS

TRANSPORTING THE MACHINE

BY RAIL S i n c e t ra n s p o r t by r a i l i s s u b j e c t t o s p e c i a l regulations, consult an approved organization.

ON A TRAILER WARNING: This machine could slip and fall from a trailer or ramp and cause serious injury. Make sure the trailer and ramps are clean. The machine should be in line with the trailer before being loaded.

Figure 22

CT02C227

WARNING: It is mandatory to remove the counterweight before undertaking any travel without the attachment or transporting the machine without the attachment.

2. Select the engine auto idle function on the right-hand lever of the control arm.

Make sure you know the safety rules and regulations before transporting the machine. Make sure both trailer and machine are fitted with the right safety equipment.

1. Place a block behind the trailer wheels. Install the trailer side extensions (if equipped).

3. Machine with attachment Place the machine in line with the trailer, with the travel reduction gears towards the access ramps. Raise the attachment and bring it to about twenty centimetres above the bed of the trailer.

IMPORTANT: In this position, the travel and steering controls are reversed.

CT02C196

4-12

Figure 21

Issued 10-02

Bur

6-34630NA

CHAPTER 4 - OPERATING INSTRUCTIONS

Figure 23

PDH0248

4. Machine without attachment

PDH0249

6. Machine with attachment

Place the machine in line with the trailer, with the travel reduction gears towards the access ramps.

IMPORTANT: In this position, the travel and steering controls are reversed.

When the machine is completely on the trailer, raise the attachment slightly and swing the upperstructure so as to bring the attachment round to the access ramp side.

PDH0250

Figure 24

CS99B518

Figure 25

5. Machine with attachment When moving from the ramps onto the trailer bed, raise the boom slightly as soon as the attachment touches the trailer so as to bring the machine level and then move forward until the machine is resting entirely on the trailer.

Figure 26

7. Machine with attachment Place the machine completely in front of the trailer and lower the attachment onto floor of the trailer.

PDH0251

Figure 27

8. Machine without attachment Place the machine completely in front of the trailer and swing the upperstructure around.

6-34630NA

Issued 10-02 Bur

4-13

CHAPTER 4 - OPERATING INSTRUCTIONS 9. Shut down the engine, remove the starter switch key, raise the function cancellation lever.

10. Make sure that all doors, hoods and access panels are correctly locked.

11. Fold the rear view mirrors inwards.

CT02C037

PDH0251

Figure 30

CS99B519

Figure 31

Figure 28

12. Machine with attachment Use blocks and chains to fasten the machine and the attachment to the trailer.

13. Machine without attachment Use blocks and chains to fasten the machine to the trailer.

UNLOADING 1. Remove the blocks and fastening chains.

2. Start the engine.

3. Lower the function cancellation lever and raise the dozer blade (if equipped).

4. Machine with attachment A. Raise the attachment to bring it a few centimetres above the trailer bed.

PDF0360

Figure 29

14. Machine ready for transport Measure the distance between the ground and the highest point of the machine. You must know the overall height. See Machine overall dimensions in the Specifications section.

4-14

B. Move slowly while raising the attachment so as to maintain it a few centimetres above the ground.

5. Machine without attachment Move the machine slowly.

6. Turn the rear view mirrors back to their correct position.

Issued 10-02

Bur

6-34630NA

CHAPTER 4 - OPERATING INSTRUCTIONS

HANDLING THE MACHINE Never handle the machine without contacting your CASE Dealer beforehand. Your CASE Dealer will provide you with the correct procedure to be followed to ensure the operation is carried out in perfect safety.

IMPORTANT: Before handling the machine, make sure the slings are in perfect condition and that they are capable of supporting the weight of the machine.

See Weights in the Specifications section.

IMPORTANT: It is imperative to use the sling points indicated on the machine decals. See Decals in the Safety/Decals/Hand Signals section.

WARNING: Handling of the machine must be done very slowly.

WARNING: Make sure that there is nobody under or near the machine while it is being handled.

WARNING: The machine must be handled horizontally.

OPERATING THE MACHINE IN WATER 1. Make sure that the bottom of the stream, or stretch of water in which you will work, can support the weight of the machine.

CT02C198

Figure 32

PARKING THE MACHINE 1. Position the machine on flat, level ground, away from soft ground, excavations or poorly shored cavities.

2. Place the upperstructure in line with the undercarriage.

3. Retract and position the attachment in the shaft of the undercarriage then dig the bucket into the ground and lower the dozer blade (if equipped) to the ground.

4. Turn the engine throttle button to low idle position and let the engine run for approximately five minutes.

2. Only the undercarriage must be below water level. The maximum water level can be up to the height of the tracks.

IMPORTANT: Never work in water if the water level is higher than the tracks.

3. Before immersing the machine, inject large quantities of fresh grease into the attachment linkages and the dozer blade (if equipped), also on the turntable and its gear teeth.

IMPORTANT: Do not operate in a fast flowing stream.

CT02C194

Figure 33

5. Shut down the engine and remove the starter switch key.

6-34630NA

Issued 10-02 Bur

4-15

CHAPTER 4 - OPERATING INSTRUCTIONS

OPERATING THE MACHINE ON SLOPING GROUND WARNING: Hillside operations can be dangerous. Rain, snow, ice, loose gravel, soft ground, etc. modify terrain conditions. It is up to you to decide if the machine can be used in perfect safety.

During hillside operations, be extra careful.

Make sure that the low speed travel is selected.

Figure 34

CT02C195

6. Raise the function cancellation lever.

When digging on a slope, avoid swinging the upperstructure towards the bottom of the slope with the backhoe bucket full. Always keep the travel reduction gears pointing down towards the bottom of the slope.

Always travel in the same direction as the slope, to prevent the machine from turning over.

TOWING THE MACHINE Towing is only authorized when the machine has broken down.

First, make sure that it can be towed without risk of further damage.

CT02C037

Figure 35

7. Lock the operator's compartment door and make sure that the hoods, lower panels and side doors are properly fastened.

8. Check that the no part of the machine is encroaching on the highway. If this cannot be avoided, set up approved traffic signs.

As far as possible try to carry out repairs on spot or contact your CASE Dealer.

WARNING: Towing is a delicate manoeuvre which is always carried out at the risk of the user. The manufacturer's warranty does not apply to incidents or accidents which occur during towing. Where possible, carry out the repairs at the site.

WARNING: The machine must be towed very slowly, over a short distance and only if it is really unavoidable.

WARNING: The operator must be the only person on the machine when towing. Make sure that nobody else is on the machine or within its working range.

CT02C187

Figure 36

WARNING: Never jump down from the machine. When leaving from the operator's compartment, or from the upperstructure, always face the machine and use the steps and access handles.

4-16

Issued 10-02

Bur

6-34630NA

CHAPTER 4 - OPERATING INSTRUCTIONS

OPERATING THE BUCKET FILLING Fill the bucket by manoeuvring the arm. Keep the bottom of the bucket parallel to the cut. The bucket teeth and blade must cut the ground like the blade of a knife. The depth of dig varies depending on the type of material.

EXCAVATING METHOD

Figure 37

PDH0493M

2

1

3

Figure 38

PDH0494M

1. CORRECT 2. INCORRECT. THE BUCKET WILL DIG IN AND CAUSE A STALL 3. INCORRECT. THE BUCKET IS PUSHED UPWARDS. THIS WILL ALSO INCREASE THE CYCLE TIME

6-34630NA

Issued 10-02 Bur

4-17

CHAPTER 4 - OPERATING INSTRUCTIONS

LOWERING THE ATTACHMENT IN THE EVENT OF A MACHINE FAILURE If the engine fails, use the following procedure to lower the attachment: 1. Turn the starter switch key to the ON position.

CT02D268

Figure 39

2. Lower the function cancellation lever.

CT02C192

Figure 40

3. Place the control lever (s) in the position corresponding to the downward movement required.

CT02C199

4-18

Figure 41

Issued 10-02

Bur

6-34630NA

CHAPTER 4 - OPERATING INSTRUCTIONS

AUXILIARY HYDRAULIC CIRCUITS CONFIGURING THE HYDRAULIC BREAKER 1. Connect the accessory to the supply valves at the end of the arm.

BD02H164

Figure 45

6. The option pedal will now control the accessory.

To configure for CRUSHER mode follow the same procedure and place the FLOW selector in position (C). See the decal on the following page and on the machine.

Figure 42

CT02E079

2. Using a hex wrench, turn the supply valves 90 degrees to the left to open them.

Figure 43

CT02E068

3. Remove the access cover to reach the flow selector valve.

CT02C186

Figure 44

4. Remove the screw (1) then bring the flow selector valve to position (B), re-install the screw (1) in position (B).

5. Make sure that the switch located on the left-hand control panel is in the desired position.

6-34630NA

Issued 10-02 Bur

4-19

CHAPTER 4 - OPERATING INSTRUCTIONS

Figure 46

KMP1183-00

4-20

Issued 10-02

Bur

6-34630NA

CHAPTER 4 - OPERATING INSTRUCTIONS

MACHINE STORAGE PREPARATION FOR STORAGE

PERIODICAL CHECKS

The following procedure applies when the machine is to be stored for a month or more. Store the machine on flat, level ground, inside a building. If a building is not available, park the machine in a dry area on planks and cover the machine with a waterproof covering. Before storing the machine, carry out the following operations:

Every month, check:

1. Clean the machine.

2. Retract the arm cylinder rod as for as possible and lower the boom until the attachment is resting on the ground.

3. Grease the machine thoroughly. The exposed surfaces of the cylinder rods should be greased or covered with a protective film. See your CASE Dealer.

1. The electrolyte level in the batteries and the batter y c harge. Recharge the batter ies if necessary.

2. The grease on the cylinder rods.

3. The fuel level in the fuel tank and the corrosive oil level in the engine. Add more if necessary.

4. The condition of all lines, connectors and clamps (rust). Grease if necessary.

5. The condition of the paintwork. Apply a coat of anti-rust treatment where necessary.

NOTE: When the machine resumes service, the film will disappear automatically.

4. Drain the fuel tank and fill with a mixture of 90% diesel fuel and 10% anti-corrosive oil. Run the engine at idle speed for five minutes to allow the anti-corrosive oil to reach the lines, filters, pump and injectors.

5. While the engine is still warm, drain the oil sump, fill with anti-corrosive oil and replace the engine oil filter.

6. When the engine is cold, clean the outer parts of the engine with diesel fuel.

7. Clean or replace the air filter element.

8. Drain the cooling system, leave the drain valves open and do not tighten the radiator cap.

9. Remove the batteries, clean the battery housings and make sure not to leave any traces of acid.

Store the batteries in a cool, dry place, where temperature is always above freezing.

10. Paint any areas where the paintwork is not good.

11. Plug the air filter inlet and the exhaust pipe.

12. Remove the starter switch key and place a “Do not operate” label on the right-hand control arm and then raise the function cancellation lever (safety bar in inward position).

13. Lock the hoods and the cab door.

6-34630NA

Issued 10-02 Bur

4-21

CHAPTER 4 - OPERATING INSTRUCTIONS STARTING UP AFTER STORAGE 1. Close the drain valves and fill the cooling system.

2. Drain the fuel tank and fill with clean diesel fuel.

3. Drain the engine sump, fill with clean engine oil and check the oil level.

4. Change the fuel filter.

5. Install the batteries.

6. Grease the machine thoroughly.

7. Check the condition of the fan drive belt and replace it if necessary.

8. Check the hydraulic fluid level and add more fluid if necessary.

9. Check the travel reduction gears oil level and add more oil if necessary.

10. Clean the cylinder rods.

11. Unplug the air filter inlet and the exhaust pipe.

12. Remove the “Do not operate” tag and start the engine, following the starting up procedure.

13. Keep a careful watch on all systems display panel lamps and indicators.

!

WARNING: Check the machine for leaks or for any parts that are broken, defective or missing.

!

WARNING: Before starting the engine, make sure that all controls are in neutral position. This prevents the machine from moving unexpectedly or an electrical appliance from starting up.

!

WARNING: Avoid running the engine in a confined place. Make sure there is adequate ventilation at all times.

4-22

Issued 10-02

Bur

6-34630NA

CHAPTER 5 - LUBRICATION, FILTERS, AND FLUIDS

Chapter 5 LUBRICATION, FILTERS, AND FLUIDS TABLE OF CONTENTS SERVICING INSTRUCTIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-3 DAILY INSPECTIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-3 HOURMETER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-4 LUBRICATION CHART . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-5 FLUIDS AND LUBRICANTS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Engine oil . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Fuel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Coolant solution . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Environment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

5-6 5-6 5-7 5-7 5-7

FLUID AND LUBRICANT CAPACITIES AND SPECIFICATIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-8 LUBRICATION POINTS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-9 Boom / Arm / Bucket lubrication . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-9 Machine Lubrication . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-11 Greasing the Turntable Teeth . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-12 Greasing the Swing Reduction Gear . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-12 FLUID LEVELS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-13 Every 10 hours . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-13 Every 250 Hours . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-13 ENGINE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Service specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Level . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Draining, Replacing the Oil Filter, and Filling . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

5-14 5-14 5-14 5-15

COOLING SYSTEM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-16 Service Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-16 Coolant Solution . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-16 Level . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-16 Draining . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-16 Rinsing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-17 Filling . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-17 FUEL SYSTEM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-18 Service Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-18 Fuel System Air Bleed . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-18 Draining the Fuel Tank . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-19 Bleeding the Water Separator . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-19 Cleaning the Water Separator Filter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-19 Replacing the Fuel Filter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-19 Filling the Fuel Tank . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-20 Cleaning the priming pump screen . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-20 RELEASING PRESSURE IN THE HYDRAULIC SYSTEM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-21 HYDRAULIC SYSTEM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-22 Service Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-22 Level in the Reservoir . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-23 Filling the Hydraulic Reservoir . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-23 Pilot Filter Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-24 Cleaning and Replacement of the Inlet Filter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-24 Return Filter Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-25 Ultra Clean Filter Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-26 Replacing the Reservoir Breather . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-26 Issued 10-02

Bur

6-34630NA

5-1

CHAPTER 5 - LUBRICATION, FILTERS, AND FLUIDS Replacing the Hydraulic Fluid . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5-27 Bleeding Air from the Hydraulic Components . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5-27 Hydraulic Breaker (Optional) - Replacing Hydraulic Fluid and Filters . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5-29 AIR FILTER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-30 Service Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5-30 Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5-30 Air Filter Restriction Indicator . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5-30 Removing the Elements . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5-30 Cleaning the Primary Element . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5-31 Cleaning the Element . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5-31 Inspecting the Element . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5-31 Cleaning the Element Housing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5-31 Installing the Elements . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5-32 SWING REDUCTION GEAR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-33 Service Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5-33 Level . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5-33 Draining and Refilling . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5-33 TRAVEL REDUCTION GEARS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-34 Service Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5-34 Level . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5-34 Draining and Refilling . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5-34

5-2

Issued 10-02

Bur

6-34630NA

CHAPTER 5 - LUBRICATION, FILTERS, AND FLUIDS

SERVICING INSTRUCTIONS Respect the maintenance intervals by checking the hourmeter every day. Before starting maintenance, park the machine on flat, firm ground, away from any obstacles, with the arm retracted and the bucket on the ground. Unless otherwise specified, all maintenance operations must be carried out with the engine stopped, and the key removed from the starter switch. It is preferable to wait for all circuits to cool down before starting work.

Clean the grease fittings before lubrication. Clean around plugs and filler holes before adding fluid. No dust or dirt must enter the components or the circuits.

Wear suitable clothing and remember to use the necessary safety equipment.

WARNING: There is a risk of serious injury if maintenance or repairs are not carried out correctly. If you do not understand maintenance procedures, consult your CASE Dealer.

IMPORTANT: Take particular care to replace all filters regularly. Clean filters mean longer engine running life.

IMPORTANT: Oil and fluid should not be thrown on the ground. They must be stored and removed by a company which is responsible for their recycling or their disposal.

SERVICE SPECIFICATIONS Intervals between overhauls are much more frequent for the following applications: construction of tunnels using a hydraulic breaker, scale stripping, foundry cleaning, operation under water etc. For special applications consult your CASE Dealer.

DAILY INSPECTIONS Every day, before starting work, it is necessary to inspect the machine and ser vice cer tain of its components.

GENERAL REMARKS Check for water or oil leaks.

WARNING: If the attachment is raised or if the machine moves without an operator, serious injury can result. Before performing any maintenance, proceed as follows: 1. Park the machine on flat, level ground.

2. Lower the attachment until it is resting on the ground.

3. Lower the dozer blade (if equipped) until it rests on the ground.

4. Shut down the engine and remove the starter key switch.

5. Lock the tracks to prevent any machine movement.

Check that all screws and nuts are correctly tightened.

Wipe off any dust (engine, operator's compartment, etc.).

Check for damage.

ENGINE C he ck t h e o i l l evel an d c ha n g e t h e o i l i f necessary.

Check the coolant level.

Check for clogging or damage to the radiator.

Check the radiator fan belt tension.

Check the air filter is clean and not restricted.

WARNING: Be sure all the service operations in this section are carried out punctually at the intervals given, in order to ensure optimum performance levels and maximum safety when using the machine.

Check for water or oil leaks on the components.

Check the condition of all lines.

UPPERSTRUCTURE Check the fuel tank level.

Check the hydraulic reservoir level.

When carrying out service work on the machine, place a Do Not Operate tag on the instrument panel.

Never climb down from the operator's compartment leaving the engine running.

Check that the hydraulic oil is clean.

Any modification to this machine without prior authorization could cause serious injury. Do not make any modifications without authorization.

Consult your CASE Dealer.

Check for electrical short-circuits.

IMPORTANT: If you use your machine in particularly harsh conditions (dusty or corrosive atmosphere, etc.), the servicing intervals should be reduced accordingly.

6-34630NA

Issued 10-02 Bur

Check for water or oil leaks on the components.

Check the condition of all lines.

Check the battery connections are properly tightened.

Adjust the rear view mirrors.

UNDERCARRIAGE Check the shoe hardware.

Check the condition of the tracks.

5-3

CHAPTER 5 - LUBRICATION, FILTERS, AND FLUIDS Check that the upper and lower rollers and the idler wheels are not leaking oil.

ATTACHMENT Check for oil leaks on the cylinders.

Check the condition of all lines.

Check the condition of the bucket teeth.

AFTER STARTING THE ENGINE Did the engine start correctly? Are the exhaust fumes normal? Any strange noises?

HOURMETER The hourmeter enables service operations to be scheduled. Its hourly indications are the same as those of a clock when the engine is running.

Ser vicing inter vals are carefully calculated to guarantee safe and efficient machine operation.

Be sure to carry out all the servicing operations properly as defined in this manual.

Check for abnor mal noise on the hydraulic components.

Check for water or oil leaks on the components.

Check the audible alarm devices, working lights and windshield wipers.

Check that all circuits (travel, swing and tool) are functioning correctly.

IMPORTANT: If the slightest defect is found, repair it immediately before using the machine or see your CASE Dealer.

Figure 1

CT02C243

5-4

Issued 10-02

Bur

6-34630NA

CHAPTER 5 - LUBRICATION, FILTERS, AND FLUIDS

LUBRICATION CHART

6-34630NA

Issued 10-02 Bur

5-5

CHAPTER 5 - LUBRICATION, FILTERS, AND FLUIDS

FLUIDS AND LUBRICANTS Lubricants must have the correct properties for each application.

WARNING: The conditions of use for individual fluids and lubricants must be respected.

Respect the maintenance intervals by checking the hourmeter every day. Before starting maintenance, park the machine on flat, firm ground, away from any obstacles, with the arm retracted and the bucket on the ground. Unless otherwise specified, all maintenance operations must be carried out with the engine stopped, and the key removed from the starter switch. It is preferable to wait for all circuits to cool down before star ting work. Wear suitable clothing and remember to use the necessary safety equipment.

Clean the grease fittings before lubrication. Clean around plugs and filler holes before adding fluid. No dust or dirt must enter the components or the circuits.

WARNING: Be sure all the service operations in this section are carried out punctually at the intervals given, in order to ensure optimum performance levels and maximum safety when using the machine.

WARNING: There is a risk of serious injury if maintenance or repairs are not performed correctly. If you do not understand the maintenance procedures, consult your CASE Dealer.

WARNING: If the attachment is raised or if the machine moves without an operator, serious injury can result. Before performing any maintenance, the following steps must be carried out: 1. Park the machine on flat, level ground.

2. Lower the attachment until it is resting on the ground.

3. Stop the engine and remove the starter switch key.

4. Lock the tracks to prevent any machine movement.

When carrying out service work on the machine, place a “Do not operate” tag on the right-hand control a r m . N eve r c l i m b d ow n f r o m t h e o p e r a t o r ’s compartment leaving the engine running.

5-6

Any modification to this machine without prior authorization could cause serious injury. Do not make any modifications without authorization.

Consult your CASE Dealer.

IMPORTANT: If you use your machine in particularly harsh conditions (dusty or corrosive atmosphere, etc.), the servicing intervals should be reduced accordingly.

IMPORTANT: Take particular care to replace all filters regularly. Clean filters mean longer engine running life.

IMPORTANT: Oil and fluid should not be thrown on the ground. They must be stored and removed by a company which is responsible for their recycling or their disposal.

HYDRAULIC FLUID CASE hydraulic fluid is specially designed for high pressure applications and for the CASE hydraulic system.

TRANSMISSION COMPONENT OIL Extreme pressure oil used for enclosed transmission components.

GREASE The type of grease to use depends on ambient temperature.

FUEL Use diesel fuel suitable for the ambient temperature conditions (ASTM-D-975).

ENGINE OIL CASE No. 1 motor oil is the oil recommended for your engine. This oil ensures correct lubrication of your engine in all working conditions.

Figure 2

CT02D203

If CASE No. 1 Multiperformance or Performance engine oil cannot be obtained, use only oil of the Oil viscosity/Oil range

Issued 10-02

Bur

6-34630NA

CHAPTER 5 - LUBRICATION, FILTERS, AND FLUIDS

A 3

1

2

4 B Figure 3

CS98M561

(A) FAHRENHEIT TEMPERATURE (B) CELSIUS TEMPERATURE (1) ALL SEASONS (2) WINTER (3) TROPICAL (4) ARCTIC (*) USE OF AN ENGINE OIL HEATER, OR AND ENGINE COOLANT HEATER IS REQUIRED.

FUEL Use fuel which is to ASTM (American Society for Testing and Materials) D975 standard.

Use grade No. 2 fuel. The use of other types of fuel can result in a loss of power of the engine and may cause high fuel consumption.

In cold weather, it is tentatively approved to use a mixture of fuels No. 1 and No. 2. Consult your fuel supplier.

If the temperature falls below the fuel cloud point (point at which wax begins to form) the wax crystals will cause power loss or will prevent the engine from starting.

In cold weather, fill the fuel tank at the end of the day's work, in order to prevent the formation of condensation.

FUEL STORAGE Long storage can lead to the accumulation of impurities and condensation in the fuel. Engine trouble can often be traced to the presence of water in the fuel.

The storage tank must be placed outside and the temperature of the fuel should be kept as low as possible. Drain off water and impurities regularly.

6-34630NA

Issued 10-02 Bur

COOLANT SOLUTION Put only ethylene-glycol coolant solution in the cooling system. Use good quality ethylene-glycol that has a high boiling point, with no additives to prevent l ea k ag e. Do n o t us e no n- ap pr oved an ti - r u s t additives. Anti-rust additives and ethylene-glycol can mix and work against each other, thereby reducing anti-corrosion protection, forming deposits in the cooling system and causing damage to the cooling system and radiator.

Contact your CASE Dealer who will supply you with the suitable coolant solution.

ANTI-FREEZE/ANTI-CORROSION Use anti-freeze in all seasons to protect the cooling system from corrosion and all risk of freezing.

For areas where the ambient temperature is over -36°C, use a blend of 50% ethylene-glycol based anti-freeze.

For areas where the temperature is below -36°C, it is advisable to use a blend of 40% water and 60% anti-freeze.

ENVIRONMENT Before carrying out any maintenance operation on this machine and before disposing of used fluids or lubricants, always think of the environment. Never throw oil or fluid on the ground and never place it in leaking receptacles.

Contact your local ecological recycling centre or your CASE Dealer to obtain information on the correct method of disposing of these lubricants.

5-7

CHAPTER 5 - LUBRICATION, FILTERS, AND FLUIDS

FLUID AND LUBRICANT CAPACITIES AND SPECIFICATIONS ENGINE Type of oil .............................................................................................................................................CASE No. 1 Capacity ...................................................................................................................................... 24 litres (6.4 gal) COOLING SYSTEM System capacity ........................................................................................................................... 23 litres (6.1 gal) FUEL SYSTEM Reservoir capacity....................................................................................................................... 265 litres (70 gal) HYDRAULIC SYSTEM Type of fluid ........................................................................................................... CASE Hy-Tran Ultra (MS 1209) Total system capacity .................................................................................................................. 205 litres (54 gal) Reservoir capacity.................................................................................................................... 120 litres (31.7 gal) TRAVEL REDUCTION GEARS Type of oil ................................................................................................... API GL5 grade 80W90 or ISO VG 150 Capacity (per reduction gear).................................................................................................... 4.7 litres (1.25 gal) SWING REDUCTION GEAR Type of oil ................................................................................................... API GL5 grade 80W90 or ISO VG 150 Capacity .................................................................................................................................... 4.8 litres (1.26 gal)

5-8

Issued 10-02

Bur

6-34630NA

CHAPTER 5 - LUBRICATION, FILTERS, AND FLUIDS

LUBRICATION POINTS BOOM / ARM / BUCKET LUBRICATION

3

5

7 4 6

1

8

2

9

Figure 4

CT02E083

Use the following grease: EP NLGI grade 2 (for temperate and hot climates) -20°C to +60°C

6

EP NLGI grade 0 (for cold climates) -40°C to +20°C The numbers within brackets mentioned on the right of the description indicate the number of lubrication points.

1

CT02E093

Figure 6

EVERY 1000 HOURS 2. Boom / Arm linkage . . . . . . . . . . . . . . . . . . . . (2)

Figure 5

CT02E084

EVERY 1000 HOURS 1. Boom foot pin . . . . . . . . . . . . . . . . . . . . . . . . . (3)

6-34630NA

Issued 10-02 Bur

5-9

CHAPTER 5 - LUBRICATION, FILTERS, AND FLUIDS

5

2

Figure 10

CT02E089 CT02E088

Figure 7

EVERY 50 HOURS 3. Boom cylinder bottom . . . . . . . . . . . . . . . . . . (2)

EVERY 50 HOURS 6. Arm cylinder top . . . . . . . . . . . . . . . . . . . . . . . (1)

7

3

Figure 11

CT02E094

CT02E085

Figure 8

EVERY 50 HOURS 4. Boom cylinder top . . . . . . . . . . . . . . . . . . . . . (2)

EVERY 50 HOURS 7. Bucket cylinder bottom . . . . . . . . . . . . . . . . . . (1)

8

4

Figure 12

CT02E090 CT02E086

Figure 9

EVERY 50 HOURS 5. Arm cylinder bottom . . . . . . . . . . . . . . . . . . . . (1)

5-10

EVERY 50 HOURS 8. Bucket cylinder top . . . . . . . . . . . . . . . . . . . . . (1)

Issued 10-02

Bur

6-34630NA

CHAPTER 5 - LUBRICATION, FILTERS, AND FLUIDS MACHINE LUBRICATION Use the following grease:

9

EP NLGI grade 2 (for temperate and hot climates) -20°C to +60°C EP NLGI grade 0 (for cold climates) -40°C to +20°C The numbers within brackets mentioned on the right of the description indicate the number of lubrication points.

Figure 13

CT02E091

9

CT02C245

Figure 15

EVERY 500 HOURS Turntable bearing . . . . . . . . . . . . . . . . . . . . . . . . . (2) Figure 14

CT02E092

EVERY 50 HOURS 9. Arm / bucket linkage . . . . . . . . . . . . . . . . . . . . (5)

CT02E105A

Figure 16

EVERY 5000 HOURS Swing reduction gear . . . . . . . . . . . . . . . . . . . . . . (1) See Greasing the swing reduction gear.

6-34630NA

Issued 10-02 Bur

5-11

CHAPTER 5 - LUBRICATION, FILTERS, AND FLUIDS GREASING THE TURNTABLE TEETH

GREASING THE SWING REDUCTION GEAR EVERY 5000 HOURS Remove the lower panel, remove the air bleed plug (1) and refill with grease through the grease point (2).

A certain amount of grease should run out from the air bleed plug (1).

1

IMPORTANT: When greasing, if the air bleed plug (1) is not removed, the inner seal will be damaged.

1 CT02E095

Figure 17

EVERY 500 HOURS

2

Remove the screws, panel and seal (1). Check for damage on the gear teeth and their condition.

If the gear surface is not well greased, add grease.

If the grease is white due to moisture content, etc. replace it with new grease.

If water accumulation is found:

Figure 18

CT02E104

1. Remove the protective panel from the lower central area.

2. Remove the plug.

3. Discharge the water or contaminated grease.

4. Install the plug.

5. Insert new grease through the port, then install the panel (1).

5-12

Issued 10-02

Bur

6-34630NA

CHAPTER 5 - LUBRICATION, FILTERS, AND FLUIDS

FLUID LEVELS

EVERY 250 HOURS

EVERY 10 HOURS NOTE: The numbers within brackets mentioned on the right of the description indicate the number of levels.

CT02E101

Figure 22

Batteries . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . (2)

Figure 19

CT02E098

Coolant solution expansion reservoir. . . . . . . . . . . (1) Ethylene-glycol and water

CT02E102

Figure 23

Travel reduction gears . . . . . . . . . . . . . . . . . . . . . (2)

Figure 20

CT02E099

Engine oil. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . (1) CASE No. 1

CT02E103

Figure 24

Swing reduction gear . . . . . . . . . . . . . . . . . . . . . . (1)

Figure 21

CT02E100

Hydraulic reservoir. . . . . . . . . . . . . . . . . . . . . . . . . (1) CASE Hy-Tran Ultra (MS 1209)

6-34630NA

Issued 10-02 Bur

5-13

CHAPTER 5 - LUBRICATION, FILTERS, AND FLUIDS

ENGINE SERVICE SPECIFICATIONS Engine oil level check ..................................................................................................... Every 10 hours or every day Oil change .........................................................................................................................................Every 500 hours Oil filter replacement..........................................................................................................................Every 500 hours Oil type ...................................................................................................................................................... Case No. 1 Oil capacity ...................................................................................................................................... 24 litres ( 6.4 gal) LEVEL 1. Park the machine on flat, horizontal ground. Shut down the engine and remove the starter switch key.

2. When the engine has been stopped for fifteen minutes, remove the dipstick (1), wipe it with a clean cloth and replace it in the guide tube as far as it will go. Then take it out again.

2

Figure 27

CT02E107

1

Figure 25

CT02E106

3. If the level is situated between the marks (A) and (B) of the dipstick, the level is correct.

B

A

CS98M579

Figure 26

4. If the oil level is at mark (A) (min) or below, remove the filling plug and add oil up to mark (B) (max) of the dipstick then install the plug.

NOTE: The level should not be higher than the mark (B) (maximum on the dipstick).

5-14

Issued 10-02

Bur

6-34630NA

CHAPTER 5 - LUBRICATION, FILTERS, AND FLUIDS DRAINING, REPLACING THE OIL FILTER, AND FILLING NOTE: Change the oil while the engine is still warm.

The oil will flow more easily.

3

1. Park the machine on flat, horizontal ground. Shut down the engine and remove the starter switch key.

3

2. Remove the oil filler cap (1).

CT02D031

Figure 30

5. Clean the area around the oil filters (3) and remove them, using a filter wrench.

6. Coat the seal of the new filter with a fine film of oil.

1

7. Install the new filter. Turn the filter until the seal comes into contact with the filter head then tighten an extra half turn by hand.

Figure 28

CT02E107

IMPORTANT: Do not use a filter wrench to tighten the filter. Excessive tightening can damage the filter and their seals.

8. Fill the engine with new engine oil. Install the filling plug.

2

9. Run the engine for a few minutes and check that there are no leaks. Check the level again and top up if necessary.

IMPORTANT: Always wait fifteen minutes to allow the oil to return to the sump before checking the oil level.

Figure 29

CT02E108

3. Place a receptacle of a suitable capacity under the engine sump drain plug, remove the plug (2) and allow the oil to flow out.

4. Put a new seal on the drain plug and install the plug.

CT02D301

6-34630NA

Issued 10-02 Bur

Figure 31

5-15

CHAPTER 5 - LUBRICATION, FILTERS, AND FLUIDS

COOLING SYSTEM SERVICE SPECIFICATIONS Expansion reservoir level check ..................................................................................... Every 10 hours or every day Checking the tightening of clamps, of radiator hoses .......................................... Every 250 hours or every 6 months Draining the system (long duration....................................................................... Every 1000 hours or every 2 years Draining the system (with anti-freeze) (spring and autumn).................................................................... Twice a year System capacity ............................................................................................................................... 23 litres (6.1 gal) LEVEL WARNING: Boiling coolant solution can The level of coolant solution should be checked spray out if the radiator cap is removed while when the engine is cold. the system is still hot. To remove the cap, On flat, level ground, before using the machine, allow the system to cool down, turn the cap to (while the engine is still cold), the level in the the first notch and wait until there is no more expansion tank should be between the Full (1) and pressure. Then remove the cap.

Low (2) marks. If not, see Filling.

WARNING: Check and service the cooling system according to the instructions given in this manual.

1

COOLANT SOLUTION Put only ethylene-glycol coolant solution in the cooling system. Use good quality ethylene-glycol that has a high boiling point, with no additives to prevent l ea k ag e. D o n ot us e no n- a p pr ove d a n ti - r u s t additives. Anti-rust additives and ethylene-glycol can mix and work against each other, thereby reducing anti-corrosion protection, forming deposits in the cooling system and causing damage to the cooling system and radiator.

Consult your CASE Dealer for suitable coolant solution.

2

Figure 33

CT02E110

DRAINING

To access the expansion tank, lower completely the swing reduction gear hood located at the front of the machine.

Figure 34

CT02E111

1. Remove the radiator cap.

WARNING: Do not remove the radiator cap when the engine is hot. The system is still under pressure and you could be scalded.

CT02E096

5-16

Figure 32

Issued 10-02

Bur

6-34630NA

CHAPTER 5 - LUBRICATION, FILTERS, AND FLUIDS FILLING 1. Fill with coolant solution via the radiator until overflowing and install the radiator cap.

Figure 35

CT02E112

2. Remove the panel located under the upperstructure and open the radiator bleed plug.

CT02E111

Figure 37

2. Fill the expansion reservoir to the Full mark and install the cap.

IMPORTANT: Use the correct coolant solution.

3. Run the engine at idle speed for about five minutes. Add coolant solution if the level in the expansion reservoir drops.

IMPORTANT: Do not fill the expansion reservoir above the Full mark.

4. Close the hood.

Figure 36

CT02E113

3. Open the drain plug located on the engine block.

NOTE: Have a receptacle of a suitable capacity ready.

RINSING 1. Close the bleed plug when the radiator is completely empty. Install the plug on the engine block.

2. Fill the system with clean water. Install the radiator cap.

3. Start the engine. Run the engine at a speed slightly higher than idle speed for ten minutes to bring the engine temperature up to about 80°C (176° F).

4. Drain the system once more.

5. Repeat Steps 1 to 4 until the water drained is clear.

6. Install the panel under the upperstructure.

6-34630NA

Issued 10-02 Bur

5-17

CHAPTER 5 - LUBRICATION, FILTERS, AND FLUIDS

FUEL SYSTEM SERVICE SPECIFICATIONS Air bleed from the fuel system .................................................................................................................. As required Fuel reservoir bleeding ................................................................................................ Every 50 hours or every week Water separator bleeding ............................................................................................ Every 50 hours or every week Fuel filter replacement .......................................................................................................................Every 500 hours Replacing the filtering element of the water separator ......................................................................Every 500 hours Cleaning the water separator filter.....................................................................................................Every 500 hours Replacing the fuel hoses ................................................ Every 2 years or every 4000 hours (whichever comes first) Fuel tank capacity............................................................................................................................ 265 litres (70 gal) Type of fuel ........................................................................................................................................................ Diesel FUEL SYSTEM AIR BLEED It is necessary to bleed the system when:

· The tank has been completely emptied. · The fuel filter has been replaced. · Parts of the fuel system have been removed for servicing or repair work.

· The machine has been in storage for a fairly long period.

1. Make sure that the fuel level in the reservoir is above the water separator filter level.

Figure 39

CS98M578

2. Loosen the knob of the priming pump (1).

Loosen the air bleed screw (2). Move the handle of the priming pump (1) up and down until no bubbles come out of the air bleed screw.

3. When bubbles no longer come out, tighten the air bleed screw (2) and tighten the knob of the priming pump (1).

4. Completely wipe off any spillled fuel. Start the engine and check for possible leakage.

1 2

CT02E114

Figure 38

WARNING: Completely wipe off any spillled fuel after replacing a filter element or bleeding the system.

5-18

Issued 10-02

Bur

6-34630NA

CHAPTER 5 - LUBRICATION, FILTERS, AND FLUIDS DRAINING THE FUEL TANK

CLEANING THE WATER SEPARATOR FILTER

The valve is located below the upperstructure on the right-hand side of the machine.

IMPORTANT: Always protect your face before using compressed air.

1. Position a drain pan under the drain plug.

2. Open the drain valve located at the bottom of the tank and drain the accumulated sediment and water.

3. After draining, close the drain valve.

To access the filter, open the right-hand rear side door.

Remove the socket head screw, then take out the filter and clean it using compressed air. Check the condition of the filter and replace it if necessary.

Install the filter and the socket head screw. (

BLEEDING THE WATER SEPARATOR To access the separator, open the right-hand rear side door.

A 2

1

Figure 40

CT02E116

Figure 41

CT02E117

WARNING: Completely wipe off any spilt fuel. It may cause a fire.

1. When the float reaches the level (A): 2. Position a drain pan under the drain plug.

3. Loosen the drain plug (1) and drain the water and sediment.

4. When the float (2) settles on the bottom, tighten the drain plug (1).

5. Verify that there are no fuel leaks.

WARNING: Completely wipe off any spillled fuel. It may cause a fire.

REPLACING THE FUEL FILTER 1. Clean the area around the filter head.

2. Place a receptacle of a suitable capacity under the filter and remove the filter, using a filter wrench.

3. Coat the seal of the new filter with a fine film of oil or grease.

NOTE: Do not fill the new filter with fuel before installing.

4. Install the new filter. Turn the filter until the seal comes into contact with the filter head and turn an extra half turn by hand.

IMPORTANT: Do not use a filter wrench to install the filter. Overtightening the filter can damage the seal and filter.

NOTE: If the engine does not regain full power after replacing the filter, bleed the system.

6-34630NA

Issued 10-02 Bur

5-19

CHAPTER 5 - LUBRICATION, FILTERS, AND FLUIDS FILLING THE FUEL TANK 1. Clean carefully around the filling cap.

2. Fill the tank, make sure that no water or dust enters the tank.

IMPORTANT: Never remove the tank filter for filling.

WARNING: Never refuel when the engine is running. Never smoke when refuelling.

IMPORTANT: In cold weather, use fuel corresponding to the ambient temperature. See Lubrication and fluids. Fill the fuel tank after each working day to prevent the formation of condensation.

3. Install the filler cap.

CLEANING THE PRIMING PUMP SCREEN

1

CT02F018

Figure 42

The screen is placed in the socket head screw (1).

Remove the screen, clean it with compressed air then rinse it in fuel.

5-20

Issued 10-02

Bur

6-34630NA

CHAPTER 5 - LUBRICATION, FILTERS, AND FLUIDS

RELEASING PRESSURE IN THE HYDRAULIC SYSTEM IMPORTANT: Before carrying out any work on the hydraulic system, there should be no pressure in any of the circuits.

1. Place the machine on flat, level ground, lower the attachment to the ground and stop the engine.

2. Turn the starter switch key to the ON position.

Figure 46

CT02C195

6. Press the button (1) located above the breather to release any possible pressure.

Figure 43

CT02D268

3. Lower the function cancellation lever.

1

CT02D050

Figure 44

CT02C038

4. Operate the control levers from right to left and front to rear a dozen times approximately.

Figure 47

WARNING: Stop the engine, press the pressure release button and completely bleed air from the reservoir.

WARNING: Make sure that you don’t get scalded with the hydraulic fluid under high pressure. The temperature should not exceed 40°C (104° F).

Figure 45

CT02D057

5. Turn the starter switch key to the OFF position (shut down).

6-34630NA

Issued 10-02 Bur

5-21

CHAPTER 5 - LUBRICATION, FILTERS, AND FLUIDS

HYDRAULIC SYSTEM SERVICE SPECIFICATIONS Check the hydraulic reservoir fluid level .......................................................................... Every 10 hours or each day Check the lines ....................................................................................................................................Every 50 hours Replace the hydraulic breaker return circuit filter (optional) ..............................................................Every 100 hours Draining water and sediment from the hydraulic reservoir ................................................................Every 250 hours Check the condition of the hydraulic fluid ........................................................................................Every 1000 hours Replace the pilot filter ......................................... Every 1000 hours (after the first 50 hours during the run-in period) Replace the reservoir breather ........................................................................................................Every 1000 hours Clean the inlet filter..........................................................................................................................Every 2000 hours Replace the return filter ...................................... Every 2000 hours (after the first 50 hours during the run-in period) Replace the Ultra Clean filter...........................................................................................................Every 2000 hours Replace the inlet filter ......................................................................................................................Every 5000 hours Change the hydraulic fluid ...............................................................................................................Every 5000 hours Capacity of the reservoir............................................................................................................... 120 litres (31.7 gal) Total capacity of the system ............................................................................................................ 205 litres (54 gal) Oil type ........................................................................................................................Case Hy-Tran Ultra (MS 1209) Replace the hoses.......................................................... Every 2 years or every 4000 hours (whichever comes first) NOTE: If the machine is new or if a major component has been overhauled or replaced in the hydraulic system, replace the pilot filter and return filter after 50 hours of operation. After that, replace these filters at the stipulated interval.

IMPORTANT: Every 1000 operating hours, it is necessary to have the hydraulic fluid analysed. See your CASE Dealer.

WARNING: Before carrying out any operation on the hydraulic filters or the hydraulic system, the pressure must be released from the system. Failure to observe this instruction can cause injury. See Releasing pressure in the hydraulic system.

IMPORTANT: After replacing the hydraulic fluid, it is necessary to bleed all air from the hydraulic components. See Bleeding air from the hydraulic components.

IMPORTANT: If metal filings are discovered in the replaced filters, see your CASE Dealer.

WARNING: Before carrying out any service work on the hydraulic system it is necessary to allow it to cool down (the temperature should not be more than 40°C (104° F).

WARNING: Hydraulic fluid or grease injected into your skin can cause severe injury or death. Keep your hands and body away from any pressurized leak. Use cardboard or paper to check for a leak. If fluid is injected into your skin, see a doctor immediately and have the fluid removed.

5-22

Issued 10-02

Bur

6-34630NA

CHAPTER 5 - LUBRICATION, FILTERS, AND FLUIDS LEVEL IN THE RESERVOIR

FILLING THE HYDRAULIC RESERVOIR

1. Park the machine on flat, horizontal ground.

Retract completely the bucket and arm cylinder rod. Lower the attachment to the ground. Shut down the engine and remove the starter switch key.

2. Using the starter switch key, open the right-hand side door.

1. Release all pressure in the hydraulic reservoir.

S e e R el e a s i ng p r e s s u r e i n th e hy d ra ul i c reservoir.

2. Clean the plate and also around the plate.

Remove the 4 screws (1) and the plate (2) then add hydraulic fluid as required.

3. The oil must be located in the middle of the indicator. Top up if necessary. See Filling.

1

CT02D068

2

Figure 50

3. Check the max and min level by monitoring the indicator.

Figure 48 Figure 49

CT02D058

6-34630NA

Issued 10-02 Bur

Install the plate (2) and the 4 screws (1). Replace the cover seal if required.

5-23

CHAPTER 5 - LUBRICATION, FILTERS, AND FLUIDS PILOT FILTER REPLACEMENT To access the filter, open the right-hand rear side door.

CLEANING AND REPLACEMENT OF THE INLET FILTER 1. Release all pressure in the hydraulic reservoir.

See Rel easing Pres sur e in the Hydraulic System.

2. Clean the top of the hydraulic reservoir and clean the inlet filter cover.

3. Remove the cover (1), O-ring (2) and spring on the top of the inlet filter rod assembly.

4. Remove the inlet filter (3) and clean with solvent.

Dry it completely and check it for any damage. If there is any damage on the surface, replace it with a new one.

5. Install a new O-ring (2) and install the inlet filter (3), spring and rod assembly.

4

6. Install the cover (1).

Figure 51

CT02E126

1. Release all pressure in the hydraulic system.

See Rel easing Pres sur e in the Hydraulic System.

7. Check the level of the hydraulic fluid and add more if necessary. See Filling the reservoir.

NOTE: Install a new inlet filter every 5000 hours of operation or when the hydraulic fluid is replaced.

2. Use a wrench on the bottom of the filter body (4) to unscrew and remove it.

1

3. Remove the old filter (3) and O-ring (2).

2

4. Clean the filter body (4) in solvent and wipe dry with a cloth.

5. Coat the new filter (3) and the new O-ring (2) with clean hydraulic fluid and install the filter on the head (1).

6. Install the filter body (4) and tighten with a wrench. Do not overtighten.

3 Figure 53

CI98M156

1

2 3 4 CS98M619

Figure 52

To access the filter, open the rear right-hand side door.

5-24

Issued 10-02

Bur

6-34630NA

CHAPTER 5 - LUBRICATION, FILTERS, AND FLUIDS 5. Remove the cover (4) and the o-ring (5).

RETURN FILTER REPLACEMENT 1. Release all pressure in the hydraulic reservoir.

See Rel easing Pres sur e in the Hydraulic System.

2. To access the filter, remove the screws (1) and the plate (2).

6. Take out the spring (6), valve (7) and return filter (8).

7. Install a new filter. Clean the spring (6) and valve (7) and install them.

8. Check O-ring (5) and replace it if worn or damaged.

9. Install the cover (4).

10. Check the level of the hydraulic fluid and add more if necessary. See Filling the reservoir.

4 2

5

6

1

7

Figure 54

CT02E127

8

3. Clean the top of the hydraulic reservoir and clean the return filter cover.

CI98M156

Figure 56

4

3 Figure 55

CT02E128

4. Remove the 4 screws (3) and the cover (4).

6-34630NA

Issued 10-02 Bur

5-25

CHAPTER 5 - LUBRICATION, FILTERS, AND FLUIDS ULTRA CLEAN FILTER REPLACEMENT

REPLACING THE RESERVOIR BREATHER

1. Release all pressure in the hydraulic reservoir.

See Rel easing Pres sur e in the Hydraulic System.

2. Clean the top of the filter with solvent.

1. Press the button (1) to release all pressure in the hydraulic reservoir.

2. Remove the nut (2) and the cover (3) from the breather.

3. Remove the four screws (1) from the cover and remove the cover (2). Remove the O-ring (3) and the spring (4).

3. Remove and discard the used filter (4).

4. Carefully lift the old filter element (6) out of the body (5).

5. Install the cover (3) as well as the nut (2).

4. Install a new element, making sure the seal (5) is facing upwards.

5. Use a clean cloth and clean out the filter body (5).

1

6. Carefully install a new filter element (6) in the body (5).

2

7. Install the spring (4), new O-ring (3) and cover (2).

3

8. Start the engine and run it at low speed.

9. Loosen the vent plug (7) on top of the cover.

When air free hydraulic fluid comes out of the vent hole, tighten the vent plug (7). Clean all fluid from the filter body.

4

5

10. Check the level of the hydraulic fluid and add more if necessary. See Filling the reservoir.

1

7

Figure 58

CS00E528

2 3

4 5 CS02A544

5-26

6 Figure 57

Issued 10-02

Bur

6-34630NA

CHAPTER 5 - LUBRICATION, FILTERS, AND FLUIDS REPLACING THE HYDRAULIC FLUID 1. Release all pressure in the hydraulic reservoir.

See Rel easing Pres sur e in the Hydraulic System.

2. Remove the reservoir filling cover.

3. Using a pump, remove the fluid from the hydraulic reservoir. Have a container with a suitable capacity ready.

1

13. Place the machine in position and then stop the engine.

14. Check the oil level in the hydraulic reservoir and add oil as required and check that ther are no air bubbles in the hydraulic reservoir.

15. Bleed the components. See Bleeding the hydraulic components.

BLEEDING AIR FROM THE HYDRAULIC COMPONENTS IMPORTANT: After bleeding air from the components, stop the engine for five minutes and check there are no bubbles at the surface of the hydraulic fluid in the reservoir.

HYDRAULIC PUMP

2

Figure 59

CT02E125

1

4. Remove the screws (1) and the tank filling cover (2).

3 CT02E132

5

Figure 60

Using a solvent, clean the upper surface of the pump and the air bleed plug. Remove the air bleed plug (1).

Fill the pump with hydraulic fluid via port (1). Install and tighten the air bleed plug.

4 5. Remove the screws (3) and the plate (4) under the upperstructure.

6. Place a container of suitable capacity under the tank drain plug and drain completely.

7. Replace the inlet filter and the return filter.

8. Install the tanik drain plug and the plate.

9. Put new hydraulic fluid into the reservoir.

Start the engine and run it at low speed. Loosen the air bleed plug (1) on the pump. Tighten the plug when air free fluid comes out of the bleed plug hole.

Clean the area completely.

ATTACHMENT CYLINDERS Start and run the engine at low idle speed. Extend and retract the attachment cylinder rods four or five times without bringing them to end of stroke. Then repeat the operation three or four times, this time bringing the cylinder rods to end of stroke.

IMPORTANT: Before you start the engine, it is very important that you bleed air from all the hydraulic components. See Bleeding Air from the Hydraulic Components.

10. Start and run the engine with no load for approximately five minutes.

11. Move each control several times to remove any air in the system.

12. Swing the upperstructure evenly left to right two complete turns or more.

6-34630NA

Issued 10-02 Bur

5-27

CHAPTER 5 - LUBRICATION, FILTERS, AND FLUIDS SWING REDUCTION GEAR

CHECKING THE HYDRAULIC SYSTEM LINES Make sure there are no leaks from the hydraulic system hoses, pipes, plugs, connections and fittings and check that all nuts and screws are correctly tightened. In the event of problems, repair, replace or tighten the component(s) concerned.

1

CT02E133

Figure 61

Start and run the engine at low idle speed. Loosen the air bleed plug (1) and make sure hydraulic fluid runs out through this port. If required, shut down the engine and top up via port (1). Install the plug without tightening, then start and run the engine at low idle, leaving it to run until oil begins to run from the orifice.

Tighten the air bleed plug (1) completely. Swing the upperstructure three times completely to the right and three times completely to the left.

5-28

Issued 10-02

Bur

6-34630NA

CHAPTER 5 - LUBRICATION, FILTERS, AND FLUIDS HYDRAULIC BREAKER (OPTIONAL) - REPLACING HYDRAULIC FLUID AND FILTERS WITH STANDARD HYDRAULIC FLUID

1 4

3

2 Figure 62

CS99A860A

1. PERCENTAGE OF USE

2. INTERVAL IN HOURS

3. REPLACING HYDRAULIC FLUID

HYDRAULIC FLUID

· When using the hydraulic breaker, hydraulic fluid deteriorates more quickly than during ordinary digging. Check the hydraulic fluid level more frequently. In addition, when replacing the filters, also check the condition of the hydraulic fluid.

4. REPLACING HYDRAULIC FILTERS

10. Start the engine and run it at low speed. Operate the hydraulic breaker and check that there are no leaks.

· Replace the hydraulic fluid and filter element using

1

7

the following graph as a reference, depending on the operation frequency of the hydraulic breaker.

2

3

· Replace the return filter for the hydraulic breaker at the same interval as the element.

RETURN FILTER

4

1. Release all pressure in the hydraulic reservoir.

See Rel easing Pres sur e in the Hydraulic System.

5

IMPORTANT: It is mandatory to use the option control pedal to release all pressure in the hydraulic breaker circuit.

2. This filter is equipped with an indicator (7). When the filter is restricted, the filter must be changed.

3. Remove the drain plug (6) and drain the hydraulic oil.

6 CS98M622

Figure 63

4. Remove the four screws (1) on top of the case and remove the cover (2), indicator and O-ring (3) assembly.

5. Replace the filter (5) with a new filter.

6. Discard the used O-rings.

7. Insert new O-rings (3) and (4) and install the assembly.

8. Tighten the retaining screws (1) for the cover (2).

9. Install the drain plug (6).

6-34630NA

Issued 10-02 Bur

5-29

CHAPTER 5 - LUBRICATION, FILTERS, AND FLUIDS

AIR FILTER SERVICE SPECIFICATIONS Inspect and clean the primary element .................. Every 250 hours or when central zone of the indicator turns red Replace the primary element ................................................................Every 1000 hours or after cleaning six times Replace the secondary element ......................................................................................................Every 2000 hours IMPORTANT: The primary element can be cleaned. The secondary element cannot be cleaned and must be replaced.

IMPORTANT: Observe the air filter service intervals shown above. Clean filters mean longer engine life.

INSPECTION To access the air filter, open the left-hand side door and secure the safety rod.

Be sure to carry out regular checks on the air filter, intake manifold, seals, and hoses. At the same time, check the intake manifold screws and hose clamps for tightness.

REMOVING THE ELEMENTS

AIR FILTER RESTRICTION INDICATOR Located below the air filter, this indicator (1) shows the state of the air filter elements. When the central zone of the indicator becomes red then the elements must be serviced, irrespective of the next scheduled service interval.

1. Release the fasteners and remove the cover.

Once the elements have been serviced, press the button on top of the indicator to start a new indication cycle.

2 Figure 65

CT02D117

2. Remove the primary element.

1 CT02F002

Figure 64

CT02D118

Figure 66

3. Remove the secondary element if it needs replacing.

IMPORTANT: The secondary element must be replaced, not cleaned.

5-30

Issued 10-02

Bur

6-34630NA

CHAPTER 5 - LUBRICATION, FILTERS, AND FLUIDS Clean it in water with a suitable detergent (consult your CASE Dealer). Instructions for using the detergent are printed on the packaging.

IMPORTANT: Allow the element to dry completely before installing it. It is advisable to keep a spare, clean element ready for installation on the air filter while the cleaned element is drying.

Figure 67

CT02D119

CLEANING THE PRIMARY ELEMENT IMPORTANT: Always protect your face before using compressed air.

If the primary element is dry: Blow compressed air from the inside towards the outside at very low pressure. The compressed air nozzle should be held at least 3 cm from the inside wall of the element. Cleaning is completed once no more dust comes out of the primary element.

PDE0088

Figure 69

INSPECTING THE ELEMENT Check the element for damage by placing an inspection lamp inside the element.

IMPORTANT: Replace the element if light can be seen through a hole, however small.

Figure 68

CT02D120

CLEANING THE ELEMENT IMPORTANT: Always protect your face before using compressed air.

PDE0378

Figure 70

CLEANING THE ELEMENT HOUSING

If the element is dry: Blow compressed air from the inside towards the outside at very low pressure. The compressed air nozzle should be held at least 3 cm from the inside wall of the element. Cleaning is completed once no more dust comes out of the element.

Remove dust from the housing of the elements and its cover.

IMPORTANT: Compressed air pressure should not exceed 7 bar (101 psi).

NOTE: Do not use compressed air if there is oil or soot in the element.

If the cartridge is greasy: 6-34630NA

Issued 10-02 Bur

5-31

CHAPTER 5 - LUBRICATION, FILTERS, AND FLUIDS

CT02D393

Figure 71

Figure 74

CT02D117

4. Check that the dust ejector under the filter is working correctly.

INSTALLING THE ELEMENTS 1. Install the secondary element.

5. Press the red button on the indicator.

IMPORTANT: If exhaust smoke is abnormal after cleaning, the air filter primary element must be replaced.

CT02D119

Figure 72

2. Install the primary element.

Figure 75

CT02D117

CT02D118

Figure 73

3. Install the cover (with the word TOP at the top) and close the fasteners.

5-32

Issued 10-02

Bur

6-34630NA

CHAPTER 5 - LUBRICATION, FILTERS, AND FLUIDS

SWING REDUCTION GEAR SERVICE SPECIFICATIONS Oil level check....................................................................................................................................Every 250 hours Draining ............................................................ Every 1000 hours (after the first 250 hours during the run-in period) Grease.............................................................................................................................................Every 5000 hours Oil capacity .................................................................................................................................... 4.8 litres (1.26 gal) Oil type ............................................................................................................................... See Fluids and lubricants DRAINING AND REFILLING WARNING: Wait till all components have 1. Park the machine on flat, horizontal ground. Stop cooled down before carrying out any the engine and remove the starter switch key. operation.

2. Remove the dipstick and the filling plug.

WARNING: Loosen the dipstick slowly to release pressure, otherwise there is a risk of oil spurting out.

1. Park the machine on flat, horizontal ground. Stop the engine and remove the starter switch key.

2. Access the swing reduction gear by opening the hood at the front of the machine.

CT02D030

LEVEL

CT02F007

Figure 78

3. Place a receptacle of a suitable capacity under the upperstructure and remove the drain plug.

4. Allow the oil to drain.

NOTE: The oil takes a relatively long time to drain.

IMPORTANT: Check the condition of the drained oil. If it contains metal filings or foreign matter, see your CASE Dealer.

Figure 76

CT02E103

1. Remove the dipstick. The level should come up to the hatched area.

5. Install the drain plug.

6. Add oil through the filler port until the level is correct.

7. Install the dipstick and the filling plug.

8. Wait ten minutes and then use the dipstick to check the level again. If necessar y, top up through the filler port.

NOTE: When greasing the swing reduction gear, see Greasing the swing reduction gear.

Figure 77

CT02F006

2. If necessary, top off through the filler port. Install the dipstick.

6-34630NA

Issued 10-02 Bur

5-33

CHAPTER 5 - LUBRICATION, FILTERS, AND FLUIDS

TRAVEL REDUCTION GEARS SERVICE SPECIFICATIONS Oil level check....................................................................................................................................Every 250 hours Draining .............................................................................. Every 1000 hours (after the first 250 hours of operation) Oil capacity .................................................................................................................................... 4.7 litres (1.25 gal) Oil type .............................................................................................................................. See Fluids and Lubricants DRAINING AND REFILLING

LEVEL 1. Park the machine on flat, horizontal ground.

1. Park the machine on flat, horizontal ground.

2. Move the machine so that plug (1) is in the lowest possible position.

2. Move the machine so that plug (1) is in the lowest possible position.

1

1

Figure 81

CT02F008

Figure 79

CT02F008

3. Stop the engine and remove the starter switch key.

3. Shut down the engine and remove the starter switch key.

4. Remove the plug (2) and check the oil level. The level must come up to the lower edge of the orifice. If required, remove the plug (3) then top up through this port (3) until oil comes up to the bottom edge of the port (2).

2

3

3

1

Figure 82

CT02F010

2

4. Place a receptacle of a suitable capacity under the travel reduction gear and remove the three plugs (1), (2) and (3).

5. Allow the oil to drain.

CT02F009

Figure 80

5. Install the plugs (2) and (3).

6. Repeat Steps 2 to 5 for the other travel reduction gear.Travel slowly with the machine and make sure there are no leaks.

IMPORTANT: Check the condition of the drained oil. If it contains metal filings or foreign matter, see your CASE Dealer.

6. Install the plug (1), fill with oil through the port (3) until oil comes up to the bottom edge of port (2), then install the plugs (2) and (3).

7. Repeat Steps 2 to 6 for the other travel reduction gear. Travel slowly with the machine and make sure there are no leaks.

5-34

Issued 10-02

Bur

6-34630NA

CHAPTER 6 - MAINTENANCE AND ADJUSTMENTS

Chapter 6 MAINTENANCE AND ADJUSTMENTS TABLE OF CONTENTS TRACKS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Maintenance Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Cleaning . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Checking the Tension . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Adjusting the Tension . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

To Reduce Tension . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

6-3 6-3 6-3 6-4 6-4 6-4

TRACK ROLLERS AND IDLER WHEELS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-6 Maintenance Specification . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-6 RADIATOR AND OIL COOLER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-7 Maintenance Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-7 Cleaning . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-7 FAN AND ALTERNATOR DRIVE BELT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Maintenance Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Checking the Tension . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Adjusting the Tension . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Replacing the Belt . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

6-8 6-8 6-8 6-8 6-8

FUEL TANK FILTER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-9 Maintenance Specification . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-9 INSPECTING AND CLEANING THE MACHINE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-9 Maintenance Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-9 ADJUSTING ROCKER ARM CLEARANCE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-9 CHECKING FOR CYLINDER LEAKAGE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-9 REPLACING A BUCKET . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-10 Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-10 Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-10 FIRE EXTINGUISHER (NOT SUPPLIED) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-11 WELDING ON THE MACHINE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-11 PLASTIC AND RESIN PARTS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-11 AIR CONDITIONING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-12 HARDWARE TORQUE INSPECTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-14

Issued 10-02

Bur

6-34630NA

6-1

CHAPTER 6 - MAINTENANCE AND ADJUSTMENTS

6-2

Issued 10-02

Bur

6-34630NA

CHAPTER 6 - MAINTENANCE AND ADJUSTMENTS

TRACKS MAINTENANCE SPECIFICATIONS Clean .......................................................................... Periodically and when the machine has been working in mud Check tension............................................................................................................................................Periodically Check shoe bolt torques .......................................Every 250 hours (after the first 50 hours during the run-in period) IMPORTANT: If the tracks are too tight, they wear quickly. If tracks are not tight enough, they wear quickly and the links can catch on the sprocket wheel or slide off the idler wheel or the sprocket wheel.

Clean the tracks after work.

4. Repeat Steps 1 to 4 for the other track.

CLEANING When the machine has been working in mud, a reduction in temperature can cause the mud to solidify.

1. Place the upperstructure at right angles to the undercarriage. Use the attachment to press on the ground and lower the boom until the track is raised off the ground.

Figure 1

CT02D176

2. Put the engine throttle button (1) on the maximum speed position and select the fast speed (2).

2 1

Figure 2

CT02D156

3. Operate the travel control lever for the raised track forwards and then in reverse, to remove the mud.

6-34630NA

Issued 10-02 Bur

6-3

CHAPTER 6 - MAINTENANCE AND ADJUSTMENTS CHECKING THE TENSION

ADJUSTING THE TENSION

1. Park the machine on flat, horizontal ground.

2. Clean the tracks.

3. Place the upperstructure at right angles to the undercarriage. Use the attachment to press on the ground and lower the boom until the track is raised off the ground.

This operation is to be carried out after the tension has been checked.

TO INCREASE TENSION 1. With the track raised, clean the grease fitting adaptor and the grease fitting.

2. Connect the grease pump. Inject grease to obtain the right amount of track sag. See Track tension value.

3. Remove the grease pump and clean the grease fitting.

4. Repeat Steps 1 to 3 for the other track.

CT02D176

Figure 3

4. Use the travel control lever to operate the raised track in reverse for a few moments.

5. Stop the engine and remove the starter switch key.

6. Measure the slack between the base of the undercarriage and the upper part of the track tread. See Track tension value.

7. Adjust the tension if necessary and then lower the raised track to the ground.

8. Repeat Steps 3 to 7 for the other track.

Figure 5

CT02D177

TO REDUCE TENSION 1. With the track in raised position, loosen the grease fitting adaptor about three turns to allow grease to flow out of the cylinder.

WARNING: Never unscrew the grease fitting adaptor completely to speed up the flow of grease. The grease in the cylinder is under high pressure.

2. As soon as the right track sag is obtained, tighten the adaptor. See Track Tension Value.

3. Clean the grease adaptor and fitting and then lower the raised track to the ground.

4. Repeat Steps 1 to 3 for the other track.

CT02D176A

6-4

Figure 4

IMPORTANT: If the grease fitting adaptor is damaged, grease may leak out. Check the condition of the grease fitting adaptor regularly and replace it if necessary.

Issued 10-02

Bur

6-34630NA

CHAPTER 6 - MAINTENANCE AND ADJUSTMENTS

Figure 6

CT02D178

TRACK TENSION VALUE The value (A) should be between: 280-300 mm (11 to 12 in) TIGHTENING TORQUE OF THE TRACK SHOE The tightening torque of the bolts should be: 300 Nm (221 ft lbs) + 120° plus or minus 5°.

Follow the prescribed order.

1

3

4

2

Figure 7

CS00E504

6-34630NA

Issued 10-02 Bur

6-5

CHAPTER 6 - MAINTENANCE AND ADJUSTMENTS

TRACK ROLLERS AND IDLER WHEELS MAINTENANCE SPECIFICATION Check ................................................................................................................................................Every 250 hours The upper (1) and lower rollers (2) and idler wheels (3) use a permanent floating seal type sealing mechanism. The service life normally lasts until overhaul, but check visually from time to time before wo r k fo r o il le ak a ge. I f oi l l ea k ag e is fou nd , component replacement is necessary. See your CASE Dealer.

3

1

2 Figure 8

CT02F013

6-6

Issued 10-02

Bur

6-34630NA

CHAPTER 6 - MAINTENANCE AND ADJUSTMENTS

RADIATOR AND OIL COOLER MAINTENANCE SPECIFICATIONS Check for leakage........................................................................................................... Every 10 hours or every day Clean .................................................................................................................................................Every 250 hours CLEANING Shut down the engine, remove the starter switch key, open the rear left-hand side door and the engine hood.

Make sure your face is protected before using compressed air.

Clean the radiator and the oil cooler: Dry dust: use compressed air.

Mud: use a water jet.

Greasy dust: use perchlorethylene.

The use of trichlorethylene is strictly forbidden.

WARNING: Before any travel operation make sure that the locking of the engine hood is correct.

1. Loosen the four wing nuts (1) and remove the two protective grilles (2) to access the radiator.

CT02F017

Figure 9

1. Loosen the four wing nuts (1) and remove the two protective grilles (2) to access the radiator.

2. Install the grilles (2) and the wing nuts (1) then close the engine hood and the rear left-hand side door.

2. Install the grilles (2) and the wing nuts (1) then close the engine hood and the rear left-hand side door.

6-34630NA

Issued 10-02 Bur

6-7

CHAPTER 6 - MAINTENANCE AND ADJUSTMENTS

FAN AND ALTERNATOR DRIVE BELT MAINTENANCE SPECIFICATIONS Visual check ................................................................................................................... Every 10 hours or every day Check belt tension .............................................................................................................................Every 250 hours CHECKING THE TENSION

REPLACING THE BELT

Use your finger to exert pressure of around 10 kg on the centre of the drive belt. The tension slack should be between about 8 and 12 mm (.3 to .4 in).

If one or more belts break, the battery indicator lights up on the instrument panel. Shut down the engine, remove the starter switch key and change the belt.

NOTE: Check if there are any signs of wear damage to the pulleys or the belt. Check carefully to ensure that the belt is correctly positioned in the pulley grooves. If the belt is stretched, cracked or frayed, it must be replaced.

IMPORTANT: If the engine runs with the belt slack, the belt can slip in its housing and cause the engine to overheat or the battery to receive insufficient charge.

Figure 12

CT02D204

1. Remove the mounting bolts (1). Use the adjustment screws (2) to push the alternator inwards.

1 2 Figure 10

CS98M560

ADJUSTING THE TENSION Remove the mounting bolts (1). Use the adjustment screws (2) to move the alternator outwards until belt tension is correct. Tighten the alternator mounting bolts (1).

1 Figure 13

CS99A852

2. Remove the belts that are worn out.

1

3. Install two new belts.

2

4. Adjust the belts using the screw (2).

5. Tighten the mounting bolts (1).

6. Run the engine for about an hour and then check the belt tension again.

IMPORTANT: The two belts have to be changed at the same time.

1

CS99A852

6-8

Figure 11

Issued 10-02

Bur

6-34630NA

CHAPTER 6 - MAINTENANCE AND ADJUSTMENTS

FUEL TANK FILTER MAINTENANCE SPECIFICATION Clean filter .................................................................................................................................................Periodically NOTE: To refill the fuel tank, see Fluids and lubricants in the Lubrication/Filters/Fluids section.

Remove the filter and clean it in diesel oil.

Figure 14

CT02F014

INSPECTING AND CLEANING THE MACHINE MAINTENANCE SPECIFICATIONS Inspect and clean ......................................................................................................................................Periodically Or whenever oil or grease has been spilt on the machine. Clean off with steam or a high pressure water jet.

Take the opportunity during this operation to make a visual check of all the welded components (in case of appearance of cracks), the attachment linkages and check the teeth and tooth tips for correct retention and for wear.

Look for any leaks and check the condition of all pipes and hoses.

ADJUSTING ROCKER ARM CLEARANCE Check ..............................................................................................................................................Every 1000 hours NOTE: Have this checked by your CASE Dealer.

CHECKING FOR CYLINDER LEAKAGE ROD APPEARANCE

TEST

Dry Slight traces of oil when a piece of paper is wiped over 20 cm of the rod.

Slightly greasy Paper remains stuck to rod when run over rod.

Oily Paper remains stuck when placed on rod.

Very oily or weeping Each time the cylinder rod is extended, a ring of oil can be seen on the rod.

CONCLUSION

Normal Normal Normal See your CASE Dealer

Leakage Each time the rod retracts, the excess oil drips from the gland.

A cylinder rod should be slightly oily. Check that there are no leaks after a period of work, when the whole hydraulic system is at nor mal operating temperature.

1. Wipe clean the rod and bearing on the cylinder to be cleaned.

2. Operate normally for five or ten minutes.

3. Extend the cylinder rod.

4. Carry out the leak test.

6-34630NA

Issued 10-02 Bur

6-9

CHAPTER 6 - MAINTENANCE AND ADJUSTMENTS

REPLACING A BUCKET REMOVAL

INSTALLATION

1. Place the bucket flat on flat, horizontal ground.

Operate the attachment controls so that the arm/bucket linkage pin is not gripped by the weight of the arm.

2. Stop the engine and remove the starter switch key.

1. Make sure the bucket is in a stable position.

2. Install the linkage seals on the arm bushing shoulders. Change them if necessary.

3. Start the engine. Extend the bucket cylinder rod to bring it into its housing. Stop the engine and remove the starter switch key.

3. Remove the retaining rings and pins.

Figure 18

CT02D212

CT02D210

Figure 15

4. Remove the bucket pins.

4. Install the arm/bucket linkage pin and then install the retaining pin and ring.

5. Start the engine. Stop the engine and remove the starter switch key.

Figure 19

CT02D213 CT02D211

Figure 16

5. Start the engine, disengage the attachment from the bucket and save the linkage seals for re-use.

6. Install the connecting rod/bucket linkage pin and then install the retaining pin and ring.

7. Push the seals back into their housings.

8. Grease the linkage pins.

CT02D212

6-10

Figure 17

Figure 20

CT02D210

Issued 10-02

Bur

6-34630NA

CHAPTER 6 - MAINTENANCE AND ADJUSTMENTS

FIRE EXTINGUISHER (NOT SUPPLIED) It is strongly recommended to have a fire extinguisher and to place it in the rear left-hand side compartment in the bracket designed for the purpose.

MAINTENANCE SPECIFICATION Every month ........................................................... examine the fire extinguisher and make sure it is not damaged.

Every six months .......................... have an approved specialist empty and refill the powder in the fire extinguisher.

Every year ...................................................................... have an approved specialist examine the fire extinguisher.

Figure 21

CS98M573

WELDING ON THE MACHINE Whenever carrying out a welding operation on the undercarriage or upperstructure carriage as authorized by the manufacturer and in accordance with his instructions, disconnect the batteries, disconnect the alternator B+ and D+ terminal wires, and connect the welding apparatus ground cable to the component on which the welding operation is to be performed.

Never connect the welding apparatus to the undercarriage when welding on the upperstructure (or vice-versa).

Never connect the welding apparatus ground to a component of the hydraulic system.

WARNING: Any unauthorized modifications made to this machine can cause serious injury. Do not undertake any modifications without first consulting your CASE Dealer.

PLASTIC AND RESIN PARTS When cleaning the plastic windows, the console, the instrument panel, the indicators, etc. do not use gasoline, kerosene, paint solvents, etc. Only use water, soap and a soft cloth.

The use of gasoline, kerosene, paint solvents, etc. will cause discoloration, cracks or deformation of these parts.

6-34630NA

Issued 10-02 Bur

6-11

CHAPTER 6 - MAINTENANCE AND ADJUSTMENTS

AIR CONDITIONING MAINTENANCE SPECIFICATION Clean the intake filter...........................................................................................................................Every 50 hours Clean the air recycling filter .................................................................................................................Every 50 hours Have checked by a specialist..............................................................................................................Every 6 months The components of the air conditioning system need servicing at regular inter vals. Make sure these intervals are respected, in order to ensure the air conditioning functions correctly and with maximum effectiveness. The air conditioning system contains gas which is subject to strict legislation. Any defect in the system must be fixed rapidly.

!

WARNING

Use your finger to exert pressure of around 10 kg (20 lbs) on the centre of the drive belt (1). The tension slack should be between about 8 and 10 mm (1/4 to 1/2 in ). If necessary, adjust the belt tension.

Tension Adjustment

!

Never try to service the air conditioning system yourself. For any service work, consult your CASE Dealer.

1

Operate the air conditioning system at least once a week, if onl y for a shor t time. See "Heati ng, ventilation or air-conditioning" in the "Controls/Instruments/Accessories" section.

2

INSPECTION In order to ensure the air conditioning functions correctly, inspect the air conditioner using the procedure outlined below before starting work.

CLEANLINESS OF THE CONDENSER If the condenser is dirty it will not dissipate heat properly. Clean the condenser in water.

Never use water under pressure to clean the condenser.

Figure 23

CT02D230

1. Loosent the pulley mounting bolt (1).

2. Use the adjustment screw (2) to move the pulley outward until belt tension is correct and tighten pulley mounting bolt (1).

CHECKING THE LINES Make a visual check of the lines and make sure there are no accumulations of dust, grease, etc.

CHECKING THE BELT TENSION

1

CT02D230

6-12

Figure 22

Issued 10-02

Bur

6-34630NA

CHAPTER 6 - MAINTENANCE AND ADJUSTMENTS CLEANING THE AIR INTAKE AND AIR RECYCLING FILTERS

Put the filters (1) and (2) in their respective housings and install the cover plate shown in figure 46.

CHECKING THE CHARGE STATE OF THE SYSTEM

1

CT02D234

Figure 24

CT02D231

1. Remove the screws and the cover plate located under the operator’s seat.

Figure 27

1. Turn on the air conditioning system, increase engine speed slightly (1400 to 1600 rpm) and look for bubbles through the sight glass (1).

2. This check should be made approximately one minute after turning on the air conditioning.

A. Very few bubbles observed, then transparent at first, then whitish: "Normal".

2

B. The bubbles are numerous: check the unions and consult your CASE Dealer.

1

C. No bubbles are visible: check the unions and consult your CASE Dealer.

Check if the hydraulic line and air-conditioning hose connectors are dirty, dusty or in need of replacing.

PLASTIC AND RESIN PARTS

Figure 25

CT02D233

2. Take out the filters (1) and (2). Use compressed air to clean the filters. If they are damaged, replace them.

IMPORTANT: Always protect your face before using compressed air.

When cleaning the plastic windows, the console, the instrument panel, the indicators, etc. do not use gasoline, kerosene, paint solvents, etc. Only use water, soap and a soft cloth.

The use of gasoline, kerosene, paint solvents, etc. will cause discoloration, cracks or deformation of these parts.

2 1

Figure 26

CT02D232

6-34630NA

Issued 10-02 Bur

6-13

CHAPTER 6 - MAINTENANCE AND ADJUSTMENTS

HARDWARE TORQUE INSPECTION MAINTENANCE SPECIFICATION Check ................................................................................................................................................Every 250 hours (after the first 50 hours during the run-in period) At the end of each working day, check all mounting nuts and screws for tightness and tighten if necessary. Make sure no hardware items are missing. Replace them, if necessary.

Screw (Ø)

Wrench (mm)

Torque setting (Nm)

Travel reduction gear (*)

M16

24

267-312

Drive sprocket (*)

M16

24

267-312

Idler wheel (*)

M16

24

267-312

Upper roller (*)

M16

30

521-608

Lower roller (*)

M16

27

371-432

Track shoe

M16

30

300+120°

M36/M30

55/46

Turntable (undercarriage)

M20

30

468-545

Turntable (upperstructure)

M20

24

468-545

Swing reduction gear (*)

M20

24

521-608

Engine (*)

M16

24

265-313

Engine mounts (*)

M10

17

64-74

Radiator

M16

24

147-176

Hydraulic pump (*)

M10 M20

17 30

63-73 367-496

Hydraulic reservoir (*)

M20

30

412-471

Fuel tank (*)

M20

30

412-471

Control valve (*)

M16

24

267-312

Hydraulic swivel (*)

M12

19

109-127

Cab

M16

24

71-86

Batteries

M10

17

20-29

Component

Counterweight

2750-2940 1520-1720

NOTE: Use Loctite 262, or the equivalent, on screws marked (*).

6-14

Issued 10-02

Bur

6-34630NA

CHAPTER 7 - ELECTRICAL

Chapter 7 ELECTRICAL TABLE OF CONTENTS FUSES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-3 Function Of The Fuses . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-4 Fuse Location . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-4 BATTERY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-5 Maintenance Specification . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-5 Access to The Batteries . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-5 Checking A Battery . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-5 Replacing the batteries . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-6 CONNECTING ONE OR TWO BOOSTER BATTERIES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-7 ALTERNATOR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-7 Maintenance Specification . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-7 STARTER MOTOR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-7 Maintenance Specification . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-7 REPLACING A BULB . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-8 Operator’s Compartment Lighting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-8 Working Lights On The Cab and On The Attachment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-8 ADJUSTING THE WORKING LIGHTS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-9 Cab . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-9 Attachment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-9

Issued 10-02

Bur

6-34550NA

7-1

CHAPTER 7 - ELECTRICAL

NOTES

7-2

Issued 10-02

Bur

6-34550NA

CHAPTER 7 - ELECTRICAL

FUSES IMPORTANT: Before changing fuses or relays, turn the starter key switch to the Shut down position.

IMPORTANT: Never replace a fuse with a fuse of a different amperage.

The fuse box is located in the operator’s compartment at the back on the left-hand side.

Figure 1

CT02D244

To access the fuses, remove the cover of the box.

A notice on the cover gives the function and amperage of each fuse.

NOTE: To remove and install a fuse, use the plastic pliers located inside the box.

NOTE: Two spare fuses (10 amp and 20 amp) are to be found on the inside of the cover.

Figure 2

CT02D245 CT02D248

6-34630NA

Issued 10-02 Bur

7-3

CHAPTER 7 - ELECTRICAL FUNCTION OF THE FUSES

FUSE LOCATION

FUSE

AMP

1

10

Memory

2

10

Key switch

3

20

Air conditioning, heater

4

10

Overload indicator controller

5

15

Working lights

6

10

Swing brake relay

7

10

Not used

8

15

7-4

FUNCTION

1

11

2

12

3

13

4

14

Windshield wiper/washer

5

15

6

16

9

10

Horn

10

15

2 flow breaker/grab option

11

15

Engine electronic box

7

17

12

15

Operator’s seat compressor (optional)

8

18

13

10

Air-conditioning and instrument panel lighting

9

19

14

10

Rotating beacon (if equipped)

15

10

Hydraulic control cancellation

10

20

16

30

Glow plugs

17

10

Travel mode relay

18

20

Not used

19

10

DC-DC (24 V - 12 V) converter

20

15

Engine emergency shut down

Figure 3

CT02E010

Issued 10-02

Bur

6-34630NA

CHAPTER 7 - ELECTRICAL

BATTERY MAINTENANCE SPECIFICATION Checking the charge state . . . . . . . . . Every 50 hours NOTE: If the machine needs to be started using a booster battery, see Connecting One Or Two Booster Batteries.

WARNING: Batteries give off explosive gases. Keep all open flames, sparks and cigarettes away. Ensure adequate ventilation when charging batteries or when using in a confined place. Always protect your eyes when working near batteries.

WARNING: Do not reverse battery terminals. Connect positive cable ends to positive (+) terminals and negative cable ends to negative terminals (-).

WARNING: Before you service a battery, always wear face protection, protective gloves and protective clothing. Battery acid or battery explosion can cause serious injuries.

WARNING: Connecting auxiliary cables wrongly or short-circuiting batteries terminals can cause an accident. Connect auxiliary starting cables as per the following instructions.

WARNING: Sparks or flame can cause hydrogen gas in a battery to explode. To prevent an explosion, do the following: 1. When you DISCONNECT the battery cables, always disconnect the negative (1) battery cable first.

2. When you CONNECT the battery cables, always connect the negative (-) cable last.

3. Do not short circuit the battery posts with metal items.

4. Do not weld, grind, or smoke near a battery.

SB034

WARNING: Always store batteries in a safe place, out of the reach of children.

SA046

WARNING: Battery acid causes severe burns. Batteries contain sulfuric acid. Avoid contact with skin, eyes or clothing. Antidote EXTERNAL: flush with water.

INTERNAL: drink large quantities of water or milk. Follow with milk of magnesia, beaten egg or vegetable oil. Call physician immediately.

EYES: flush with water for 15 minutes and get prompt medical attention.

SB032

WARNING: When the battery electrolyte is frozen, the battery can explode if, (1) you try to charge the battery, or (2) you try to jump start and run the engine. To prevent the battery electrolyte from freezing, try to keep the battery at full charge. If you do not follow these instructions, you or others in the area can be injured.

ACCESS TO THE BATTERIES To access the batteries, open the rear left-hand side door.

Remove the wing screw, washer and protective matting from the batteries.

CHECKING A BATTERY Make sure the batter y terminals are clean and coated with grease and that the cables are properly tightened.

Check the charging state and the electrolyte level using the indicator on the battery: Green: Normal.

Black: Recharge the battery.

White: Change the battery.

SA033

WARNING: Before any operation on the components of the electrical circuit, put the key switch in the shut down position. When disconnecting the battery cables, always disconnect the negative (-) cable first. When reconnecting the battery cables, always connect the negative (-) cable last.

6-34630NA

Issued 10-02 Bur

7-5

CHAPTER 7 - ELECTRICAL REPLACING THE BATTERIES

INSTALLATION

REMOVAL 1. Remove the terminal sleeves, disconnect the negative terminals (1) and then the positive terminals (2).

1

1. Install new batteries. Clean the cables and battery terminals and coat them with grease.

2. Install the holding frame, the washers and tighten the screws.

3. Connect the cables (positive terminal), the cables (negative ter minal) then install the terminal sleeves.

2

WARNING: Do not invert battery terminals.

Connect positive cable ends to positive (+) terminals and negative cable ends to negative terminals (-).

2 1

WARNING: Always store batteries in a safe place, out of the reach of children.

Figure 4

CT02F025

2. Remove the screws, the washers and the holding frame (3).

WARNING: Never allow the battery terminals to contact unprotected skin, electrolysis can occur inside the human body and damage vital organs.

3

Figure 5

CT02F026

3. Remove the screws, washers and the elbow (4).

4

CT02F027

Figure 6

4. Remove the batteries.

5. Clean the battery compartment, remove all foreign bodies, clean any spilt electrolyte.

7-6

Issued 10-02

Bur

6-34630NA

CHAPTER 7 - ELECTRICAL

CONNECTING ONE OR TWO BOOSTER BATTERIES

ALTERNATOR MAINTENANCE SPECIFICATION

WARNING: Connecting auxiliary cables wrongly or short-circuiting batteries terminals can cause an accident. Connect auxiliary starting cables as per the following instructions.

M a ke s u r e t h a t t h e b o o s t e r b a t t e r y vo l t a g e corresponds to the voltage system of the machine.

1. Remove the protective mat, if necessary.

Check . . . . . . . . . . . . . . . . . . . . . .Every 1000 hours WARNING: Whenever carrying out a welding operation on the machine (authorised by the manufacturer and in accordance with his instructions) or any repairs on the electrical system, disconnect the B+ and D+ wires from the alternator.

When reconnecting, check the markings on the wires.

2. Remove the terminal sleeves.

3. Connect the positive (+) auxiliary cable to the positive (+) terminal of the battery or the first battery of the machine.

4. Connect the negative (-) auxiliary cable to the negative (-) terminal of the battery or the second battery of the machine.

5. Start the engine.

6. Disconnect the negative (-) auxiliary cable then the positive (+) auxiliary cable from the booster batteries.

7. Install the terminal sleeves.

8. Install the protective mat, if necessary.

Do not use steam cleaning equipment or a cleaning solvent to clean the alternator.

Ask your CASE Dealer to check the alternator.

Make sure that the terminal protectors are correctly installed.

STARTER MOTOR MAINTENANCE SPECIFICATION Check . . . . . . . . . . . . . . . . . . . . . .Every 1000 hours Ask your CASE Dealer to check the starter motor.

NOTE: Make sure that the terminal protectors are correctly installed.

6-34630NA

Issued 10-02 Bur

7-7

CHAPTER 7 - ELECTRICAL

REPLACING A BULB OPERATOR’S COMPARTMENT LIGHTING 1. Remove the cover.

Figure 10

‘CT02D262

CT02C058

Figure 7

3. Pull the clip outwards, remove the bulb and install a bulb of the same wattage:

2. Remove the bulb and install a bulb of the same wattage (6 W).

CX75SR: 55 W for lights on the cab and on the attachment.

3. Install the lens.

CX135SR: 55 W for lights on the cab and 70 W for light on the attachment.

IMPORTANT: Never put your fingers on a tungsten iodide bulb.

4. Install the clip and reconnect the plug.

5. Put the working light back into position and install the mounting screws.

CT02D267

Figure 8

WORKING LIGHTS ON THE CAB AND ON THE ATTACHMENT 1. Remove the 4 retaining screws.

Figure 11

CT02D263

CT02D261

Figure 9

2. Tilt the working light and disconnect the plug.

7-8

Issued 10-02

Bur

6-34630NA

CHAPTER 7 - ELECTRICAL

ADJUSTING THE WORKING LIGHTS CAB Cab working lights are adjusted manually.

Figure 12

CT02D265

ATTACHMENT Attachment working lights are adjusted manually.

CT02D264

6-34630NA

Issued 10-02 Bur

7-9

CHAPTER 7 - ELECTRICAL

NOTES

7-10

Issued 10-02

Bur

6-34630NA

CHAPTER 8 - SPECIFICATIONS

Chapter 8 SPECIFICATIONS TABLE OF CONTENTS ENGINE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-3 ELECTRICAL SYSTEMS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-3 HYDRAULIC SYSTEM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-3 Control Valves . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-3 Swing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-3 Travel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-3 CAPACITY OF SYSTEMS AND COMPONENTS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-4 WEIGHTS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-4 GROUND PRESSURE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-4 ATTACHMENT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-4 ARMS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-4 ESCO BUCKETS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-5 CX225SR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-5 MACHINE OVERALL DIMENSIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-6 WORKING RANGE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-8

Issued 10-02

Bur

6-34550NA

8-1

CHAPTER 8 - SPECIFICATIONS

8-2

Issued 10-02

Bur

6-34550NA

CHAPTER 8 - SPECIFICATIONS

ENGINE Make ................................................................................................................................................................. ISUZU Type ........................................................................................................................................................... BB-6BG1T Number of cylinders...................................................................................................................................................6 Bore/stroke ....................................................................................................... 105 mm x 125 mm (4.13 in x 4.92 in) Displacement.............................................................................................................................. 6494 cm3 (396 CID) Power EEC 80/1269 ......................................................................................................................... 105 kW (140 hp) Speed rating .................................................................................................................................................1950 rpm

ELECTRICAL SYSTEMS Circuit ..............................................................................................................................................................24 volts Batteries ......................................................................................................................................... 2 x 12 volts/92 Ah Alternator .............................................................................................................................................. 24 volts/50 Ah Starter mtor ........................................................................................................................................ 24 volts/4.5 kW Circuit fitted with watertight connectors.

HYDRAULIC SYSTEM Variable displacement axial piston Max flow ............................................................................................................................................. 2 x 190 l/min Safety valve max pressure.

Attachment ..................................................................................................................................................343 bar Upperstructure swing ..................................................................................................................................304 bar Travel ...........................................................................................................................................................343 bar CONTROL VALVES Four control valve sections for left-hand travel, boom/bucket and arm acceleration.

Five control valve sections for right-hand travel, swing, arm, auxiliary attachment and boom acceleration.

Boom/arm load holding valves.

SWING Fixed flow, piston-type pump.

Max upperstructure swing speed .................................................................................................................11 rpm TRAVEL Variable flow hydraulic double motors with axial pistons.

Planetary reduction gears, automatic multiple disk brake.

Two speeds controlled from the instrument panel.

Low speed .......................................................................................................................................... 0 to 3.9 km/h High speed ............................................................................................................................................ 0 to 5 km/h

6-34630NA

Issued 10-02 Bur

8-3

CHAPTER 8 - SPECIFICATIONS

CAPACITY OF SYSTEMS AND COMPONENTS Hydraulic reservoir....................................................................................................................... 120 litres ( 31.7 gal) Hydraulic system ............................................................................................................................. 205 litres (54 gal) Travel reduction gear (each) .......................................................................................................... 4.7 litres (1.25 gal) Swing reduction gear..................................................................................................................... 4.8 litres (1.26 gal) Engine (with filter change) ................................................................................................................ 24 litres (6.4 gal) Fuel reservoir................................................................................................................................... 265 litres (70 gal) Cooling system ................................................................................................................................. 23 litres (6.1 gal)

WEIGHTS With 800 mm (31.5 in) shoes, 5.70 m (18 ft 8 in) boom, 3.00 m (9 ft 10 in) arm, 650 kg (1 430 lb bucket and 5 870 kg (12 940 lb) counterweight ................................................................................................... 23 300 kg (51 376 lbs)

GROUND PRESSURE 2

With 800 mm (31.5 in) shoes .................................................................................................. .37 kg/cm (5.22 psi)

ATTACHMENT Excavator boom............................................................................................................................. 5.70 m (18 ft 8 in))

ARMS 3.0 m (9 ft 10 in) 2.40 m (7 ft 10 in)

8-4

Issued 10-02

Bur

6-34630NA

CHAPTER 8 - SPECIFICATIONS

ESCO BUCKETS CX225SR

Figure 1

H . . . . . . . . . . . . Heavy material to 3 370 lbs/cu. yd.

M . . . . . . . . . . . Medium material to 2 700 lbs/cu. yd.

L. . . . . . . . . . . . . . .Light material to 2 020 lbs/cu. yd.

6-34630NA

Issued 10-02 Bur

8-5

CHAPTER 8 - SPECIFICATIONS

MACHINE OVERALL DIMENSIONS 2.40 m (7 ft 10 in) arm

Figure 2

CT02F028

A. B. C. D. E. F. G. H. I. J. K. L. M. N.

8-6

..................................................................................................................................................3.14 m (10 ft 8 in) ....................................................................................................................................................2.97 m (9 ft 8 in) ..................................................................................................................................................8.93 m (29 ft 4 in) ..................................................................................................................................................6.70 m (21 ft 9 in) ....................................................................................................................................................2.80 m (9 ft 2 in) ....................................................................................................................................................1.40 m (4 ft 7 in) ..................................................................................................................................................4.46 m (14 ft 7 in) ....................................................................................................................................................2.85 m (9 ft 4 in) ..................................................................................................................................................3.66 m (12 ft 1 in) ....................................................................................................................................................2.39 m (7 ft 8 in) ...................................................................................................................................................800 mm (31.5 in) with 800 mm shoes ...................................................................................................................3.19 m (10 ft 4 in) ....................................................................................................................................................0.46 m (1 ft 5 in) ....................................................................................................................................................1.40 m (4 ft 7 in)

Issued 10-02

Bur

6-34630NA

CHAPTER 8 - SPECIFICATIONS 3.00 m (9ft 10 in) arm

Figure 3

CT02F028

A. B. C. D. E. F. G. H. I. J. K. L. M. N.

.....................................................................................................................................................2.90m (9 ft 6 in) ....................................................................................................................................................2.97 m (9 ft 8 in) .................................................................................................................................................8.85 m ( 29 ft 0 in) ..................................................................................................................................................6.62 m (21 ft 8 in) ....................................................................................................................................................2.80 m (9 ft 2 in) ....................................................................................................................................................1.40 m (4 ft 7 in) ...................................................................................................................................................1.68 m (5 ft 6 in ) ..................................................................................................................................................4.46 m (14 ft 7 in) ..................................................................................................................................................3.66 m (12 ft 0 in) ....................................................................................................................................................2.39 m (7 ft 9 in) ...................................................................................................................................................800 mm (31.5 in) ..................................................................................................................................................3.19 m (10 ft 6 in) ....................................................................................................................................................0.46 m (1 ft 6 in) ........................................................................................................................................................1.40 (4 ft 7 in)

6-34630NA

Issued 10-02 Bur

8-7

CHAPTER 8 - SPECIFICATIONS

WORKING RANGE 2.40 M (7 FT 10 IN) ARM

Figure 4

CT02F029

A. B. C. D. E. F. G. H.

8-8

Maximum reach ....................................................................................................................... 9.37 m (30 ft 9 in) Maximum reach at ground level ...............................................................................................8.07 m (30 ft 1 in) Maximum digging depth ...........................................................................................................6.10 m (20 ft 0 in) Maximum digging depth over a length of 2.44 m .................................................................... 5.89 m (19 ft 4 in) Maximum dump height ............................................................................................................ 7.63 m (25 ft 0 in) Maximum working height ...................................................................................................... 10.52 m (34 ft 6 in) Minimum attachment swing radius ............................................................................................ 2.54 m (8 ft 3 in) Maximum digging depth - vertical wall .................................................................................... 5.48 m (18 ft 0 in)

Issued 10-02

Bur

6-34630NA

CHAPTER 8 - SPECIFICATIONS WITH 3.00 M (9 FT 10 IN) ARM

Figure 5

CT02D273

A. B. C. D. E. F. G. H.

Maximum reach ....................................................................................................................... 9.91 m (32 ft 6 in) Maximum reach at ground level ............................................................................................ 9.73 m (31 ft 11 in) Maximum digging depth ...........................................................................................................6.70 m (22 ft 0 in) Maximum digging depth over a length of 2.44 m .................................................................... 6.52 m (21 ft 5 in) Maximum dump height ............................................................................................................. 8.02m (26 ft 4 in) Maximum working height .................................................................................................... 10.91 m (35 ft 10 in) Minimum attachment swing radius ............................................................................................ 2.30 m (7 ft 6 in) Maximum digging depth - vertical wall .................................................................................. 6.06 m (19 ft 11 in)

6-34630NA

Issued 10-02 Bur

8-9

CHAPTER 8 - SPECIFICATIONS

NOTES

8-10

Issued 10-02

Bur

6-34630NA

CHAPTER 9 - INDEX

Chapter 9

INDEX A Adjusting the working lights ................................. 7-9 Air filter .............................................................. 5-30 Air flow direction ................................................ 3-11 Air recycling ....................................................... 3-11 Air vents ............................................................. 3-22 Air-conditioning switch ....................................... 3-11 Alternator ............................................................. 7-7 Ashtray .............................................................. 3-17

B Battery ................................................................. 7-5 Battery charge indicator lamp .............................. 3-8 Boom and bucket right-jand control lever .......... 3-13

C Cab light ............................................................ 3-15 Cab radio compartment ..................................... 3-17 Capacity of systems and components ................. 8-4 Checking for cylinder leakage ............................. 6-9 Coat hanger hook .............................................. 3-16 Components, Machine ......................................... 1-3 Controls locking lever .......................................... 3-9 Cooling system .................................................. 5-16

Fuel system ........................................................5-18 Fuel tank .............................................................3-24 Fuel tank filter .......................................................6-9 Fuse box .............................................................3-17 Fuses ....................................................................7-3

G General Information ..............................................1-1 Greasing the turntable teeth ...............................5-12 Ground pressure ..................................................8-4

H Hand signals .......................................................2-15 Handling the machine .........................................4-15 Hardware torque inspection ...............................6-14 Heating and ventilation control .............................3-9 Heating, ventilation or air-conditioning control .....3-9 High speed travel switch ............................ 3-8, 3-10 Horn ......................................................................3-9 Hourmeter .................................................... 3-7, 5-4 Hydraulic system ................................................5-22

I

D

Identification Numbers ..........................................1-5 Inspecting and cleaning the machine ...................6-9 Instrument panel ........................................... 3-6, 3-7

Daily inspections .................................................. 5-3 Decals ................................................................ 2-10

L

E Emergency shut down switch .............................. 3-9 Engine ........................................................ 5-14, 8-3 Engine coolant temperature indicator .................. 3-7 Engine electric circuit indicator lamp ................... 3-8 Engine hood ...................................................... 3-25 Engine idle speed selector .................................. 3-6 Engine oil pressure indicator lamp ...................... 3-7 Engine operation ................................................. 4-7 Engine throttle button .......................................... 3-6 Environment ........................................................ 5-7

F Fan and alternator drive belt ................................ 6-8 Fire extinguisher ................................................ 6-11 Fluid and lubricant capacities and specifications . 5-8 Fuel level indicator ............................................... 3-7 Fuel level indicator lamp ...................................... 3-8 6-34630NA

Issued 10-02 Bur

Left-hand control arm ...........................................3-9 Levels .................................................................5-13 Lower front window ............................................3-22 Lubrivation points .................................................5-9

M Machine Components ..........................................1-3 Machine lubrication ............................................5-11 Machine overall dimensions .................................8-6 Machine storage .................................................4-21 Machine travel ....................................................4-10

O On/Off .................................................................3-11 One-piece boom/dipper/bucket lubrication ...........5-9 Operating temperature Bringing the machine up to ..............................4-6 Operating the backhoe bucket ...........................4-17 Operating the machine .........................................4-3 Operating the machine in cold weather ................4-8 9-1

CHAPTER 9 - INDEX Operating the machine in hot weather ................. 4-9 Operating the machine in water ......................... 4-15 Operating the machine on sloping ground ......... 4-16 Operator's seat .................................................. 3-18 Option control ...................................................... 3-9 Option pedal ...................................................... 3-15 Overheating indicator lamp .................................. 3-7

P Parking the machine .......................................... 4-15 Personal Safety ................................................... 2-4 Plastic and resin parts .............................. 6-11, 6-13 Position of the operator’s compartment controls and accessories ................................................... 3-5 Preheating indicator lamp .................................... 3-8 Product Identification Number ............................. 1-5

R Radiator and oil cooler ......................................... 6-7 Rear right-hand side window ............................. 3-16 Releasing pressure in the hydraulic system ...... 5-21 Replacing a backhoe bucket ............................. 6-10 Replacing a bulb .................................................. 7-8 Right-hand control arm ........................................ 3-6 Rotary light .......................................................... 3-9 Run-in period ....................................................... 4-4

Tracks ...................................................................6-3 Transporting the machine ...................................4-12 Travel control ......................................................3-14 Travel reduction gears ........................................5-34

U Undercarriage .......................................................8-3 Unlocking and locking of pedals .........................3-15 Upper hood .........................................................3-24 Utility Safety Rules Message ................................2-4

V Ventilation ...........................................................3-11

W Weights ................................................................8-4 Welding on the machine .....................................6-11 Windshield defroster ...........................................3-11 Windshield washer reservoir ..............................3-25 Windshield washer switch .......................... 3-8, 3-10 Windshield wiper switch ............................. 3-8, 3-10 Working light switch .................................... 3-8, 3-10 Working range ......................................................8-8

S Safety Area .......................................................... 2-4 Safety/Decals/Hand Signals Safety Rules .................................................... 2-3 Utility Safety .................................................... 2-4 Serial Numbers .................................................... 1-5 Servicing instructions ........................................... 5-3 Side doors ......................................................... 3-26 Sides of the machine Right-hand, left-hand, front, and rear .............. 1-4 Speaker compartments ..................................... 3-17 Starter motor ........................................................ 7-7 Starter switch ....................................................... 3-6 Steps and access handles ................................... 3-4 Stopping the engine ............................................. 4-7 Storage tray ....................................................... 3-17 Storing the machine ........................................... 4-21 Swing reduction gear ......................................... 5-33

T Temperature ...................................................... 3-11 Towing point ...................................................... 3-26 Towing the machine .......................................... 4-16 Track rollers and idler wheels .............................. 6-6 9-2

Issued 10-02

Bur

6-34630NA